Symrise is a leading international supplier of the innovative flavour and fragrances. Symrise is one of the world's leading companies in the flavour and fragrance industry since 1874. Its range includes products that are essential features of everyday life today. They are used by food manufacturers or perfumes.
Symrise is one of the four biggest suppliers on the global market for fragrances and flavors and currently holds a market share of 10 per cent. The company develops and produces more than 30,000 products from around 10,000 raw materials; it sells these products in some 160 countries. Symrise generates roughly 40% of sales in rapidly growing emerging markets.
In the food flavours and nutrition, Symrise products range is as below,
Flavour for food, beverages, and health care products,
Alcoholic and nonalcoholic beverages
Soups, sauces , convenience food and snacks
Confectionery, bakery products, dairy products, ice-cream
Food supplements, health care and specialty products
Symrise in Corby manufactures snack flavours and culinary products. Today's consumers demand and expectations are more than just old, traditional style of some salty snacks. In the recent concepts such as dipping, finger foods etc., snacks are convenience food and form part of the daily diet. Snack foods are becoming a routine trend with natural, fresh and irresistible ingredients. Symrise's creative excellence in flavour, seasoning composition, outstanding application, technology expertise and sensory-consumer science make Symrise capable in snack food flavours.
Symrise has grasped the culinary art of cooking, roasting and frying on industrial scale, in the culinary segment. Symrise's short and gentle preparation approaches preserve both their typical, fresh taste and their authentic, natural character. Symrise offers meat flavourings in every conceivable variety and ethnic combinations with the advantage of molecular excellence and outstanding creative flavour work.
1.2 Spices and Seasonings
The term 'spices' means any aromatic vegetable substance in a whole, broken or ground form, except for those substances that have been traditionally regarded as foods, such as onions, garlic and celery; whose significant function in food is seasoning rather than nutritional.(Underriner and Hume, 1994)
Seasonings are combinations containing one or more spices, or spice extractives, which when added to a food before it served to boost the natural flavour of the food and thereby increase its acceptance by the consumer.(Underriner and Hume, 1994) Symrise is manufacturing various flavours in seasoning form to enhance or to impart the flavour in crisps, chips, biscuits.
Successful blending requires an understanding of the physics and chemistry of powders and liquids and the impact of several complex processing methods. (Graham and Annesley, 1999). In the production of seasoning blends include: mixing, liquid dispersion, extraction, agglomeration, size reduction and various physical influences of conveying, filling and packaging. All of these processes, the ingredients and atmospheric conditions (e.g. temperature, humidity, handling times) interact with one another.
Moreover, the successful compounder will have a strong knowledge of governmental regulations applicable both to the regions in which the goods are produced, as well as the regions to which the seasonings are shipped ad consumed.(Underriner and Haume, 1994). Symrise is in 35 countries including UK, so it is very essential to know the government regulations about ingredients, restrictions and labeling of each and every country. Labeling is always of critical concern, not just regarding ingredients list, but the positioning on labels of various required data, in legally acceptable format.
Ingredients used in seasonings are not necessarily compatible with one another. Chemical composition, moisture (water activity), storage temperature and influences of light and oxygen are all important considerations in achieving a successful seasoning blend (Underriner and Haume, 1994). Final test of its acceptability is the ultimate application to which the seasoning will be put.
Spices are used in seasonings in several forms. Mostly whole ground spices are used in preparation of seasonings. Alternatively, an extractive of the spice may be preferred for several reasons. Extra strength may be desirable for a given weight of spice component; hence a concentrated oleoresin or essential oil might be preferred (Underriner and Hume, 1994). The application may be of very pale, uniform colour, hence a soluble extractive might be desirable to avoid introduction of spice particulates. Rapid flavour impact and low cost may justify a plated spice (e.g. oleoresin or essential oil coated on the surface of a salt or dextrose filler). Alternatively, flavour retention and slow release may be desired, thus justifying the use of a higher cost, more stable encapsulate (Underriner and Hume, 1994).
Several critical points must be considered in the formulation of food seasonings. First of course an appropriate combination of spices, herbs and related ingredients must be selected in order to characterize the food. It must then be considered how the ultimate consumer might modify the food through use of fresh ingredients to ensure ultimate compatibility. Flavour composition is only one factor in seasoning delivery; particle size also has a significant impact, as does processing method, the use of acids, salt and presence of trace ingredients.
Routinely samples of seasoning blends are monitored for several characteristics, all of which must be controlled to ensure batch to batch uniformity and satisfaction of customer and producer specifications. Particles of dry blend are critical, since non-uniformity may result in stratification and separation of component ingredients. Salt content, measured quickly and accurately on appropriate aliquot samples of a production batch, can provide a ready indication of the uniformity of mixing step. In low salt, or salt free systems, another indicator may be appropriate such as calcium ions, measured by titration when tri calcium phosphate is used as flow agent (Underriner and Hume, 1994).
1.3 There are two prospects of seasonings,
Buyers (Consumer) outlook
Industrial expectation
Buyer outlooks
Two related consumer categories need to be clearly identified in order to properly discuss their expectations. The ultimate consumer -the one who eats the food dedicates his expectations through the food delivery and production channels.
Recent health, nutritional and ecological considerations have resulted in an increasing consumer demand for 'Natural' things. The consumer infers some innate goodness from natural, as opposed to 'artificial' from which is often inferred a lack. (Underriner and Hume, 1994). To address this subject sensibly, the European Commission has offered definitions with regard to flavours as shown in Table
Type
Description
Natural flavours
Flavours obtained from animal or plant raw materials by microbiological, physical or enzymatic processes. It should not contain any natural identical or artificial substances. It can be used in either natural state or processed for human consumption.
Nature-identical flavours
Flavours are obtained by synthesis or secluded through chemical processes that are chemically identical to flavouring substances naturally present in products envisioned for human consumptions. They must not contain any artificial flavours.
Artificial flavours
Flavoring elements not recognized in a natural product envisioned for human consumption, whether or not the product is processed. These are typically produced by fractional distillation and additional chemical manipulation naturally sourced chemicals or from crude oil or coal tar.
Traditionally natural flavours have been relatively expensive. Frequently they do not hold up well under the rigours of processing technologies. (E.g. high heat, microvave). In some cases, it may be necessary to incorporate unique process to ensure desired performance. Flavour ingredients may require encapsulation, for example in a heat labile material so that flavour is not prematurely released, and perhaps dissipated before its impact is desired. Careful attention to formulation and required labeling will enable this problem and its remedy to be legally, as well as consumer responsively, handled.
All seasoning manufacturers including Symrise are challenged to ensure that formulations adhere strictly to the laws and definitions, since the consumer expects 'Natural'.
1.3.1.1Consistency
Achieving sensory (flavour, aroma, texture, visual) consistency in seasoning is bit difficult. In the seasonings various raw materials are used such as agricultural products, essential oils, herbs, spices, natural flavours, colours etc. agricultural products vary dramatically due to varietal differences, seasonality, climatic variations, sources and quantities of nutrients during each growing phase, harvesting conditions and storage before use . The more ingredients used in seasoning , the greater the chances for errors and inconsistencies. So to reduce all these errors several actions must be carried out such as inspections of raw ingredients according to its specifications, storage of raw ingredients, sensory tastes of several ingredients etc.
1.3.2 Food Processor (Industrial) expectation
In attempting to satisfy customers, Industry requires similar attention from suppliers- in other words ingredients purchased must meet specifications on a consistent basis. Symrise has got raw material section in which it maintains more than 800 ingredients. There are more than 800 ingredients which are used in making of seasoning. Some of them are natural, some of them are natural identical and some of them are artificial flavour.
So it is very important to have specifications for each and every ingredient to maintain quality. Variations, some indeed being unavoidable as noted previously, cause at the least the need for adjustment or standardization, and at the worst, delays in production or loss of product. Thus, suppliers should be expected to support their customers just as support for the retail consumer has been outlined above, but with an added sense of urgency to avoid economic loss resulting from the customer having to shut down a production operation for non-performance or inadequate performance by the supplier.
However, additional requirements must be considered, in programmes:
To reduce the quantity and types of ingredients required (and thus the inventory carrying costs).
Ingredients reduction:
In any seasoning industry, reduction of ingredients is given much important because it would save cost and complexity as well. The ingredient control function is performed by blending the critical ingredients according to the customer's proprietary formulation, and then typically packaging the blend in 'unit' quantities, that is, the amount needed for one production batch of the food for which it has been prepared. Thus the responsibility for uniformity of formulation, at least for the multiple and critical seasoning components, is taken on by the supplier, coincidently minimizing the support activities necessary at the plant and reducing the risk of quantity variations and un warranted ingredient substitutions.
Ingredients reduction may take another, rather different form. In efforts to create new, exciting and different foods, the product development technologist often seeks new and varied ingredients, frequently resulting in a proliferation of ingredients all used in rather small quantities. An alternative reduction programme reviews similar ingredients used for similar purposes to identify those functional requirements that could be met by a single ingredient in several applications. How many different beef flavours are required to produce the various meat entrees and sauces? How many different salt granulations are required? And so on. Sometimes substitution cannot be made without sacrificing quality or product differentiation; in many cases, however, substitution can be made without noticeable differences in the finished product.
To accommodate changes in legislation such as salt or sodium content, usage of artificial flavours, allergens like celery, soy sauce powder, fish powder, mustard flavour etc. Beside these there are several barriers which need to be eliminated. The barriers to be eliminated are
Physical barriers (e.g. customs stoppages between member nations)
Technical berries (which obstruct the standardization of compay's products for business in all member states without the need for differing specifications).
There are four important technical berries which Symrise has to take in under considerations such as,
Restrictions on the use of certain ingredients.
Content and description regulations
Packaging and labeling regulations
Specific import restrictions
1.4 Seasoning ingredients
Seasoning, which is added to any species of food to give it a higher relish; usually something pungent or aromatic, as salt, spices or other aromatic herbs, acids, sugar, or a mixture of several things. Basically seasonings are used to impart flavour in any food. Symrise has got more than 800 types of ingredients; different ingredients are used for different applications.
From comparisons of total volumes of spices and herbs in commerce compared with that which is consumed from retail outlets, it is reasonable to assume that most of these ingredients are used by industrial food processors - either seasoning blenders supplying the food processing industry, or processors doing their own blending, or both. The compounding of seasonings is both an art and a science. Successful compounding requires knowledge of many ingredients. The ingredients and flavours are used in either spray dried form or liquid form.
Those most typically used in seasonings may be found in the following ingredient categories:
Spices and herbs:
Natural, whole or ground
Dried, frozen, freeze-dried, fresh
Plated (coated/adsorbed on inert fillers)
Encapsulates, concentrated and/or adjusted to natural equivalency
Oleoresins, water miscible
Extracts and essential oils
Hydrolysates/autolysates:
Animal proteins
Vegetable proteins
Yeasts
Flavour enhancers
Monosodium glutamates
Maltitol
Ribonucleic acid
Salt (In various flake types and particle sizes)
Flavours:
Compounded
Processed
Dairy components:
Acids and neutral whey fractions
Cheese powders
Caseinate
Oils (used in small percentages to minimize dusting)
Fillers:
Sugars
Starches
Gums
Grains
Preservatives and antioxidants
Anticaking or flow improvement agents (usage varies by legal jurisdiction)
Silicon dioxide
Tri- calcium phosphates
Some of the ingredients which are being used in Syrise are listed below,
Vegetable powders such as onion powders, tomato powder, garlic powder, carrot powder etc.
Herbs and spices such as mace, sage, basil, paprika with different size, chilli powder, turmeric, cayenne, ginger etc.
Dairy powders such as cheese powder, lactose powder, cheddar cheese, yogurt powder, cream powder, whole milk powder, skim milk powder, sour cream powder etc.
Food colours such as paprika 60000 c.u and 100000 c.u (C.U defines the strength of the colour), annatto colour etc.
Liquid flavours such as cheese concentrate, ham flavour, chicken flavour, freid onion flavour, smoke flavour, tomato flavour, onion flavour, natural acetic acid, natural meat flavour, chilli flavour, bacon flavour, mace flavour etc.
Some fillers are used which are mixed with natural or natural identical flavours to bind the flavours, those ingredients are lactose powder, dextrose powder, rice flour, wheat flour roasted etc.
Some allergens are also used such as celery powder and flavour, prawn flavour, shrimps flavour, soy sauce powder, mustard flavour and powder etc.
Among these ingredients or flavour some of them are natural, some of them are natural identical.
So the flavours are developed on the basis of customers' requirements. Some of the customers allow, using artificial flavours or natural identical flavours. But it seems that most of the customers prefer to use natural flavours because of restrictions in legislations and most important is market. Consumer wants food products made from natural ingredients. Symrise avoids using artificial flavours. Natural ingredients cost much as compare to natural identical or artificial flavours.
1.5 Aim of project
As it is mentioned earlier, that Symrise is manufacturing seasonings for snacks and culinary products, the work has been done in seasonings segment. Symrise is making several types of seasonings by using more than 800 ingredients. So, in a broad spectrum, Aim of the project was "To gain thorough understanding of flavours, development of flavours and carrying several sensory tastes".
The projects were given, are listed below,
Project 1: To understand each and every ingredient that includes spray dried powders, dried flavours, liquid flavours, natural flavours, natural identical flavours, allergens.
Project 2: Developments of Late night snacks flavour.
Project 3: Chequer foods ltd. one of the company's customer, which faces the problem of powder filling in sachets. A project was given to improve the process and flowability of powder so that it gets desired property.
Project 4: Development of flavours for Pom Bear shaped snacks for children.
Project 5: Triangle tastes of various samples help in approval of the flavour, those has been prepared in R & D lab.
Project 6: Development of flavours called Java and Bali for prawn based pallets.
Project 7: One of the customers wants a match of some seasoning mix and pastes; the products were,
Beef flavour mix
Vegetable flavour mix
Chicken flavour mix
Vegetable paste
Chicken paste
Lamb paste
Beef paste
The task has been given, to develop these six seasoning mix and pastes similar as customer requirements.
Project 8: A project was given for development of Umami flavour
Chapter 2
Materials and Methods
2.1 Project 1: Understanding of Ingredients
Symrise (Corby) has got more than 800 ingredients. There must be deep understanding of all flavours; it requires lot of practice and proficiency. Factors like the top notes and their concentration and how they affect in flavour perception are important. The compounding of seasonings is a very specialized skill. The proper blending of dissimilar constituents such as spices extracts, salt, sugar, dairy products, emulsifiers, preservatives and many other components that enter into complex seasoning mixtures, requires a high level of technical expertise and practical experience.
Spray dried powders were taken in small amounts and spread it on a tongue to have a proper taste and aroma. Liquid flavours have been sensed and sniffed. Some of the liquid flavours were quiet strong or very concentrate, so they have been sniffed bit away from the nose.
Few ingredients and flavours that were tasted and sniffed are listed below,
Nos.
Ingredients/flavours
Herbs and spices
Chili powder
Sage ground
Mace ground
Basil ground
Basil leaves
Black pepper
Allspice
Aniseed
Rosemary ground
Cardamom
Celery
Chives
Cinnamon
Cloves ground
Ginger
Fenugreek seed ground
Fennel seed ground
Mustard seed ground
Spearmint ground
Oregano
Nutmeg
Cumin ground
parsley
thyme
Turmeric
Vegetables powders
Different types of Onion powder
Tomato powder
Carrot powder
Garlic powder
Natural and natural identical liquid and spray dried flavours
Tomato flavour
Bacon flavour
Ham flavour
Concentrate onion flavour
Sage flavour in oil
Celery seed oil
Vanilla flavour
Meat flavour
Concentrate garlic flavour
Lemongrass flavour
Chicken flavour
Black pepper flavour
Smoke dextrose
Smoke salt
Shrimps flavour
Prawn flavour
Fish flavour
Molasses flavour
Lemon flavour
Apricot flavour
Sweet flavour
Flavour enhancer
Table salt
Finer salt
Sea salt
Monosodium glutamate
ribonucleotide
Additives
Tri calcium phosphate
Silicon dioxide
Food colours
Paprika oleoresin 600000 CU
Paprika oleoresin 100000 CU
Annatto colour
Flavours made by processing
10 to 14 types of yeast extracts
Hydrolyzed vegetable protein
2.2 Project 2: Development of late night snacks flavours
A customer wanted late night snack flavours. Process of making flavour and quality aspects were considered for making a flavour. The process flow chart of making a flavour is shown in figure
C:\Users\kunal\Desktop\Untitled.jpg
In rest of the projects, all the flavours were developed by using same process flow chart as shown above.
2.3 Somakon
In the R & D lab several flavours were developed in different amount. Some of the flavours were supposed to make in large quantity. So to make flavour in big quantity, an equipment called Somakon was used. There were different bowls of different sizes. The bowls were fixed and all the ingredients were mixed on different rpm levels. The picture of somakon is shown below,
http://www.somakon.de/resources/MP-$C3$9Cbersicht.pdf
2.4 Flowability test
Purposes and scope:
By means of this method the flowability of powders were measured. Some of the Symrise's customer asked for flowability because of in some process it is essential such as packing flavour/seasonings in sachets, spraying flavours on the crisps by small orifice. So flowability of seasoning/flavours does matter in some processing.
Principle
Determination of the product quantity which flows through a standardized, round sieve machine. This machine has an automate sieve drive, which turns 15*2 times within and for 15 seconds.
Apparatus
Balance, ± 1g
Drying chamber for sieve drying
Reagents
Water and solvent for sieve cleaning
Procedure
500g substances (±2 g) temperate to room temperature (approx. +20°C) are weighed in exactly into the examiner. Product which is falling through the sieve has to be refilled in sieve. If a product has visual components, it has to be removed by sieving over a 1 mm sieve before using the sieve.
The product is sieved into a tarred receiver. This process is supported by a star shaped insert whose wings perform a circular back and forth motion. To guarantee a repeatable sieving, the movement is set to 15 repetitions. The sieves of the examiner is cleaned after use with water or solvent and dried. It has to be sure that sieves are properly cleaned and dried before taking another sample.
So this is how the flowability of the seasoning or flavours were to be measured and recorded in the product specifications.
Methods
2.5.1 Idea funnel
Almost all the given projects were based on NPD (New product development). To develop new flavour or idea is require several steps. Below in figure , it's shown that in the starting lots of ideas are being undertaken to develop new flavour. Definition of the project should be clear for an e.g. if a customer wants a flavour for pallets, crisps, biscuits or chips. Some specific requirements have been taken in consideration such as salt content, dosage level (level to which seasoning is applied on the base); base frying (pallets), allergens and NOFNOC (non- artificial flavours and non- artificial colours). So these requirements must be taken carefully to move ahead. There must be a stock of all raw materials because in seasoning industry many ingredients are needed to make flavour. C:\Users\kunal\Desktop\Funnel.gif
Now once the concept is clear several relevant flavours were made by using process as shown above in figure .
After developing a number of flavours, sensory tests were carried out with employees of Symrise to ensure that flavour meets customer requirements. After sensory some of the flavours were rejected and some of them were accepted. Accepted flavours were modified according to feedback of sensory tests.
Once they were made, again sensory tests were carried out and after that flavours have been finalized. Once the flavour was finalized, specifications were made such as salt or sodium content, application rate, allergens, ingredients and suitable according to EU regulations.
Ref: nosc.noaa.gov
Chapter 3
Results
3.1 Project 1 Understanding of ingredients their taste and flavour
After tasting of all ingredients the results were recorded and some of them are as shown in table
Ingredient
Sensation
Responsible chemical
Spray dried mustard and flavour
-
Allyl isothiocyanate
chilli
Burning, numbing, tingling, stinging, biting
Capsaicin
Cinnamon
Stinging/pricking; numbing; burning
Cinnamaldehyde
Vinegar or fruit flavour
-
Citric/aceitic acid
Cumin
Burning; tingling; numbing
Cuminaldehyde
cloves
numbing
Eugenol
Ginger
Burning, numbing, tingling
gingerol
Horseradish
-
2-propenyl/ 2-phynyleehtyle isothiocyanate
Mint
Menthol
Cooling, numbing, burning, tingling, stinging
salt
Numb, stinging/pricking
Sodium chloride
Ref: taste and aroma
3.2 Project 2 Development of late night snacks flavour
One of the company's customers asked to develop late night snack flavour. From the name of the flavour, it is clear that customer wanted a flavour which can be suitable in night. There were several flavours developed such as cheese and Worcester, kebab, pepperoni, pepperoni pizza, chips and cheese, chips and gravy. The ingredients which were used to make these flavours are shown in table
Nos
Pepperoni pizza
Kebab
Cheese and Worcester
1
Wheat flour toasted
Onion powder
Cheddar cheese powder lactosan
2
Whey powder
Salt
Salt
3
Salt
Wheat flour toasted
Sugar
4
Yeast extract
Fat powder
Sweet Whey powder lactosan
5
Cheese powder
Garlic powder
Wheat flour toasted
6
Finer salt
Yeast extract
Yeast extract
7
Finer sugar
Sugar
Onion powder
8
Onion powder
Sour cream powder
Aroma type cheddar spray dried flavouring
9
Garlic powder
Whole milk powder
Vinegar powder from malt extract
10
Pepper black ground of 60 mesh
Cumin ground
Citric acid
11
Pepper black extract on salt
Spearmint ground
Tri calcium phosphate
12
Chili powder
Chili powder
Spice flavour for Worcester sauce
13
Origanum ground
Silicon dioxide
Cayenne -pepper extract on salt
14
Cumin ground
Paprika oleoresin 60000 CU
Pepper black extract on salt
15
Tri calcium phosphate
Coriander seed ground
Silicon dioxide
16
Ginger ground
Pepper black ground of 60 mesh
Paprika oleoresin 60,000 CU
17
Aroma type bacon SD
Vegetable oil
Vegetable oil
18
Mace ground
Spray dried raw onion flavouring
19
Paprika oleoresin 60.000 CU
Liquid concentrate meat flavour
20
Cayenne pepper extract on salt
Liquid concentrate onion flavour
21
Silicon dioxide
Natural aroma type sour cream spray dried flavour
22
Beef type flavour concentrate SD
23
Lactic acid
24
Vegetable oil
Project 3 Improve flowability
A company named chequer foods is a leading industry of filling sachets with flavours, ketchup, salt, sugar. Symrise is supplying flavours to them. They were facing problem of filling of sachets with two flavours.
Mexican chili
Green thai
So the project was to investigate the problem. The filling machine was investigated while working. It was noted that how the flavours are filled in sachets and what causes the problem of filling. After vising company, it has been occurred that, the flowability of flavours were poor. Another complaint from the company was, one of the flavours was quiet dusty.
So in both of flavours silicon dioxide has been added and taken several trials. The flowability of both the flavours was measured after adding flowing agent. But still in the Mexican chili the results were quiet miserable. Several times the flowing agent has been added and measured the flowability. In the final, both the flavours have got good flowability and chequer food has taken trial in a small scale with good outcomes.
Project 4 Development of flavours for Pom Bear snacks
The project was to develop flavour for Pom Bears which already exists in the UK market. There were some requirements such as sodium content shouldn't exceed 20%. The flavours must suits for children so there must be less usage of allergens, natural identical flavour and some chemicals. The flavours were made using idea funnel as shown in figure . All the flavours were tried on the base of pom bears. The dosage rate was 5%. The pallets were fried in sunflower oil for 15 seconds at 190°C.
Some of the flavours were finalized and they are,
Hot dog & onion
Hot dog & ketchup
Cheese and ham
Pizza
Roast chicken
Roast beef
Bacon
Sweet fruity curry
The ingredients/flavours which were used to make these flavours are as shown in table as in descending order by weight.
Nos
Hot dog and onion
Hot dog and ketchup
Pizza
Sweet fruity curry
Bacon
Roast chicken
1
Onion powder
Sugar
Icing sugar
Lactose
Lactose
Maltodextrin
2
Sugar
Salt
Salt
Salt
Salt
Salt
3
Salt
Tomato powder
Sugar
Sugar
Onion powder
Whey powder
4
Yeast extract
Onion powder
Lactose
Whole milk powder
Smoke dextrose
Lactose
5
Lactose powder
Yeast extract
Onion powder
Yeast extract
Yeast extract
Yeast extract
6
Potassium chloride
Lactose powder
Yeast extract
Onion powder
Dextrose monohydrate
Onion powder
7
Citric acid
Potassium chloride
Cheese powder
Coconut milk powder
Sugar
Sugar
8
Sage leaves ground
Citric acid
Tomato powder
Turmeric ground
Ham type flavouring
Garlic powder
9
White pepper ground
Sage leaves ground
Vinegar powder from malt extract
Garlic powder
Spray died bacon flavour
Furfuryle mercaptan
10
Black pepper ground
White pepper ground
Oregano ground
Ginger ground
Vegetable oil
Vegetable oil
11
Garlic powder
Black pepper ground
Citric acid
Coriander seeds
Paprika oleoresin 60000 cu
Lactic acid
12
Vegetable oil
Garlic powder
Sage leaves ground
Fenugreek seeds
Thyme leaves ground
13
Concentrate onion flavour
Vegetable oil
Cheddar aroma flavour
Fried curry type flavouring
Citric acid
14
Silicon dioxide
Concentrate tomato flavour
Basil leaves ground
Citric acid
Tricalciaum phosphate
15
Natural mustard flavour (SD)
Silicon dioxide
Vegetable oil
Tri calcium phosphate
Chicken flavour SD
16
Concentrate meat flavour
Natural mustard flavour (SD)
Paprika oleoresin 60000 cu
Silicon dioxide
Silicon dioxide
17
Malic acid
Tomato flavour sundried
Concentrate cheese flavour
Chilli powder
Paprika oleoresin 60000 cu
18
Cayenne
Concentrate meat flavour
Concentrate tomato flavour
Tomato flavouring sun dried
Mace extract
19
Mace oil flavour
Malic acid
Tricalciaum phosphate
Turmeric extract
20
Paprika oleoresin 60000 cu.
Cayenne
Sour cream flavour
21
Mace oil flavour
22
Paprika oleoresin 60000 cu.
The salt content of all these flavours were calculated and they are as shown in table
Hot dog and onion
Hot dog and ketchup
Pizza
Sweet fruity curry
Bacon
Roast chicken
Salt content
17.6%
17.6%
15%
15%
18.2%
19.5%
Project 5 Triangle tests
Triangle test is a discriminative form of sensory analysis. The results of the triangle tests indicate whether or not detectable differences between two samples. In the triangle test always three samples are prepared, out of two samples are standard and one is add.
Triangle test was done for several samples such as Bali flavour as mention in project , beef, vegetable, chicken mixes and pastes as mention in project . Along with this participated in the triangle test of which the flavours were prepared by staff.
There could not be statistic evaluation because there were less than 20 panels.
project 6 Development of Bali and Java flavour
A customer wanted a match for Bali and Java flavour. These flavours are applied on prawn based pallets. These flavours have market in other European countries. The dosage rate should be 5 % and cost should be much than customer expectations.
Prawn based pallets were fried in sunflower oil for 25 seconds at 188°C. Several flavours were made and carried our sensory tests with staff. But still the flavour is not finalized yet. The flavours which were very close to the standard samples, their ingredients are shown in table . But still work needs to be done on these flavours.
Nos
Bali
Java
1
Sugar
Salt
2
Malto dextrin
Fructose ground
3
Salt
Glucose syrup powder
4
Yeast extract
Onion powder
5
Parsley leaves 0.3-0.5 mm size
Garlic powder
6
Indian curry powder
Monosodium glutamate
7
Chicken flavour SD
Sugar
8
Coriander seeds
Yeast extract
9
Raw onion extracte
Parsley leaves, 0.3-0.5 mm
10
Chilli powder
Roast meat dry flavour
11
Cumin ground
Coriander seed
12
Disodium 5-guanylate
Indian curry powder
13
Parsley leaves oil
Vegetable stock type flavouring
14
Rosemary ground
Caramel sugar syrup powder
15
Furfuryl mercaptan sd
Citric acid
16
Celery flavouring sd
Lemon flavour SD
17
Curry extract
Ribotide
18
Chilli extract
Vegetable oil
19
Lemongrass oil
Nutmeg ground
20
Paprika oleoresin 100000 cu
Silicon dioxide
21
Citric acid
Fenugreek extract
22
Chilli extract SD
23
Lemongrass oil
24
Turmeric extract
25
Paprika oleoresin 100000 CU
Project 7: Matching of flavours with standard samples
There was a requirement to match a flavour profile of,
Beef flavour mix
Chicken flavour mix
Vegetable flavour mix
Beef flavour paste
Chicken flavour paste
Vegetable flavour paste
Lamb flavour paste
Standards of these samples have been given and work was to be done on flavour, taste, aroma, colour and cost as well. The customer's expectations about cost were quiet high. Cost was a significant factor because all the ingredients were supposed to be cheap and easily available from suppliers. Several flavours were made and carried out triangle tests as mention in project 5, to ensure the flavours were matched with standard samples.
In results, vegetable, chicken flavour mix and pastes as well, were finalized. But beef, lamb flavour mix and pastes were yet to be finalized.
Chapter 4
Discussion
5.1 Project 1
When we taste something, we can identify the difference between the salty, sweet, sour and bitter flavour. The project was to taste and sniff all the flavours and trying to memorize all the flavour. The science behind the taste of flavour is; tongue and top of the mouth are covered with thousands of minute taste buds. The saliva helps to break down of the flavour/food. There are several receptors that are located in the taste buds, they sense the taste and give signals to a brain. The brain immediately tells that what flavour we are consuming.
Taste buds can recognize four basic tastes such as sweet, salty, bitter and sour. As in the figure, different portions of a tongue taste different. So while having dried flavour or powder, responses were memorized and it helped to develop further flavours.C:\Users\kunal\Desktop\tastebud.gif
There were several ingredients such as herbs & spices, salt, MSG, dried flavours, extracts, oleoresins, hydrolyzed vegetable protein, yeast extracts and food colours.
Herbs and spices
A general distinction between herbs and spices is that herbs are mild and used for delicate flavouring and are considered better when they are fresh, while spices are pungent and give a piquant flavour of their own to the seasoning. There are some liquid flavours such as Basil, lemongrass oil, chili flavour, celery in veg oil, concentrate garlic etc. These liquid flavours are too concentrated that it has to be added in seasoning between 0.1 to 0.6% otherwise these flavour will dominate the taste and aroma.
Natural flavours
It is important to understand the complexity of flavour selection because flavours can be very specific to certain applications. The natural flavours are available as below,
Essential oils: Essential oils are derived from spices or other odorous plants by distillation. They are highly concentrated, uniform in flavour and stable under proper storage conditions. Essential oils are mostly soluble in alcohol and vegetable oils.
Oleoresins: Oleoresins are natural plant exudates or concentrated botanical extracts prepared by solvent extraction and subsequent evaporation of the solvent, resulting in a mixture of volatile essential oils, non-volatile oils, colour, fats and other extractable substances. These represent the total flavouring constituents of spices in very concentrated form. Oleoresins are usually diluted to make them easier to disperse.
Extracts: Extracts are aromatic compounds produced by treating a natural raw material with a solvent, which is sometimes concentrated by removing some or all of the solvent.
Encapsulated flavours: Essential oils and oleoresins can be mixed with solution of gums following which coacervation is induced to cause the coating material to precipitate around the flavour droplets, thus 'encapsulating' them. These flavours are expensive but they are highly concentrated and more stable than the original raw material.
Spray dried flavour: Its quiet well known method of converting oil or water based liquid flavours into dry form. A solution is mixed with a carrier, forced through a nozzle or centrifugal device to produce a mist, which is then heated to evaporation to produce small dried particles of flavour material.
Natural with other natural flavour: this refers to a class of natural flavours that contains characterizing flavours and natural flavouring material from other sources, which simulate, look like or enhance the describing flavour.
Flavours made by processing
Hydrolyzed vegetable protein (HVP): They are the most common used in place of meat flavourings. They are available in wide range of colours and flavours characteristics those are dependent on the source of protein, such as wheat gluten, maize gluten or soy bean protein etc. HVP tastes like savoury flavour so they are used in seasonings to have a savoury flavour.
Yeast extract: There are various yeast extracts are used to make flavour. They induce savoury flavour in it. Mostly baker's yeast is preferred to give savoury flavour. The flavour of the end product is usually determined by the type of yeast and the nature of the substrate.
Flavour enhancers
A flavour enhancer is sometimes called as 'flavour potentiator'. It is a substance that is added in seasonings to supplement or intensify its original flavour. Salt plays an important role in flavour enhancing. In the almost all seasoning salt is the major content. Symrise has got three types of salt.
Normal table salt
Sea salt
Finer salt
Sea salt is obtained by the evaporation of sea water. Because of its mineral content it gives the different taste from the table salt. Finer salt is used where the instant taste of salt is required. It gives instant salty taste while eating. Fine, powdery salts are used to coat snack foods such as potato chips, pallets etc.
The other flavour enhancers are monosodium glutamate and nucleotides. Monosodium L-glutamate is the most commonly used substance to enhance flavour. The physiological phenomenon that results from tasting these ingredients is called 'Umami'. Umami is a taste common to meat, fish, certain vegetables, mushrooms and cheese; it is a taste quality represented by glutamates and 5-nucleotides. The hedonic properties are different from those of primary tastes such as salt, sweet, sour and bitter. So it has been considered as another primary taste. Glutamates (salts of glutamic acid) are good to impart flavour in seasoning.
Food colours
Colour is the first characteristics perceived by a consumer and is vital as a means of identification and eventually, acceptance of seasonings. Both the quality and the flavour of seasonings are closely associated with colour. Symrise is using various colours such as paprika, annatto, turmeric etc. All these colours are in natural form. These colours are used in different strength. For example there are two types of paprika. One is paprika 60,000 c.u and second is paprika 100,000 c.u. C.U terms as strength of a colour. If more C.U then the colour would be more concentrate or strong.
Savoury flavour
5.2 project 2
To develop any flavour, flavourist should have deep understanding of recent trends in flavours, products and their ingredients. For example in this projects pepperoni pizza, cheese and Worcesternd, kebab flavours were developed. So flavourist should have understanding of all these products and ingredients. From those ingredients, flavours and spray dried powders are selected from the flavour library.
From those ingredients, the flavour is developed by adding several flavour enhancers or concentrate flavours. Generally in the night, flavours would be preferred which could be creamy, buttery, relishing etc. In the end it depends on the individual perception that what flavour consumer would prefer.
According to these ideas several flavours have been identified. Such as Cheese and Worcester, kebab, pepperoni, pepperoni pizza, chips and cheese, chips and gravy. These new flavours have been developed. To develop these flavour, each recipe required more than 20 ingredients. So there should not be any stock out situation in the factory. If there is a shortage of any of these ingredients then the flavour profile might affect. However, if there is a stock out situation of any of the ingredients then it has to be replaced with another ingredient that gives the same taste and aroma.
The reason behind choosing cheese and Worcester was to make the flavour cheesy, creamy with onion flavour, black pepper and little bit flavour of Worcester sauce. The Worcester sauce and different yeast were added to give the savoury flavours. Usually consumer prefer the flavour which is quiet savoury.
For e.g. Symrise has got three different types of onion powders, those powders have different tastes. But while making flavour cost must be taken in consideration because it is very difficult to reach customer's expectation in seasoning industry. There should be minimal cost. So if an ingredient or flavour costs much then it has to be replaced with a flavour or ingredient that has less cost but quality shouldn't be sacrificed.
While making seasoning there are several additives which need to be added. In the seasonings liquids and spray dried powders are used. Each powder has different particle size. But it is essential that flavour should flow properly otherwise it creates problem to season the crisp, chips or pallets. It would be difficult to spray the powder on crisps or to fill the sachets. So for flowability silicon dioxide, as an anti-caking agent is used. It is used in 0.5 to 1% as per the size of particles. As a preservative tri calcium phosphate is used in 0.4 to 0.8% in seasoning/flavour. It gives shelf life of 6 months.
Project 3:
The reason behind using silicon dioxide is, some of the powders are very hygroscopic that means they absorb the moisture or water from the atmosphere very quickly. Water absorbance is a big problem in all spray dried powders. So they form lumps in powder. It creates problem in flowing or in processing. To avoid such situation silicon dioxide is added in all flavours.
Project 6:
In the development of the flavours Bali and Java
- http://www.knovel.com/web/portal/knovel_content?p_p_id=EXT_KNOVEL_CONTENT&p_p_action=1&p_p_state=normal&p_p_mode=view&p_p_col_id=column-1&p_p_col_count=1&_EXT_KNOVEL_CONTENT_struts_action=/ext/knovel_content/view&_EXT_KNOVEL_CONTENT_contentType=2&_EXT_KNOVEL_CONTENT_SpaceID=0&_EXT_KNOVEL_CONTENT_VerticalID=0&_EXT_KNOVEL_CONTENT_SetID=9129685&_EXT_KNOVEL_CONTENT_BookID=2141&_EXT_KNOVEL_CONTENT_NodeID=370552&_EXT_KNOVEL_CONTENT_Associated=true&_EXT_KNOVEL_CONTENT_SearchMode=false&sistring=&ststring=
http://investor.symrise.com/english/equity-story/profile.html
http://www.symrise.com/en/our-world/flavor-nutrition/savory.html
http://books.google.co.uk/books?id=hrWuqmtwJiEC&pg=PA273&lpg=PA273&dq=savoury+seasoning+process+flow+chart&source=bl&ots=IspsYiFoAU&sig=ePbrPLjDWR3pik-QN8vz5v_6ftM&hl=en&ei=2F9pTKS4DsuTjAfapP3UBA&sa=X&oi=book_result&ct=result&resnum=1&ved=0CB0Q6AEwADgK#v=onepage&q&f=false
http://library.thinkquest.org/3750/taste/taste.html
http://www.shvoong.com/exact-sciences/5671-food-science-triangle-test/
