As the COVID-19 pandemic escalated in 2020, the food scientists and culinary team at Ingredion faced a significant challenge: the innovation of the cherished french fry. With restaurants largely closed and many relying on takeout for the majority of their sales, there was an urgent need for fries that maintained their golden crispness while revealing a soft, inviting interior for longer periods. The shift in food consumption and purchasing habits required a prompt reevaluation of how to achieve this goal. “With COVID, it became essential; we can’t deliver to the consumer in just a few minutes when it comes to home delivery,” stated Greg Aloi, vice president of customer co-creation and innovation at Ingredion.
Leveraging their extensive knowledge about the shelf life of french fries, Ingredion acted swiftly. They understood that a potato’s high amylose starch content creates a protective barrier that initially helps delay sogginess. However, more information was needed quickly, prompting Ingredion to ask its clients a series of questions: How will the french fry be produced and manufactured? Will a coating be applied? What type of fry is it—shoestring, crinkle-cut, or curly? Within three months, which is rapid for ingredient development, they made significant strides. By modifying the crispy coating to allow moisture to escape as the fries cooled, they extended the shelf life of a delicious fry from just five minutes to between 15 and 25 minutes.
From this initial achievement, Ingredion created tailored solutions based on the type and moisture content of the potato, as well as the fry’s size and shape. They also considered various factors such as the fry’s temperature at the time of delivery and the location of sale, whether in Florida or Minnesota. Once primarily recognized as a specialty starch supplier, Ingredion has aggressively expanded its offerings under CEO James Zallie, amassing over 1,300 ingredients. The company has pursued mergers and acquisitions along with partnerships to incorporate more texturizers, plant-based proteins, clean and simple ingredients, sugar reduction, and specialty sweeteners to meet the evolving demands of consumer packaged goods (CPGs) and their buyers.
This diversified portfolio has proven advantageous for Ingredion in the current unpredictable business landscape, as many CPGs utilizing its ingredients face supply chain disruptions, rising costs, and increasing consumer demands. Mike DiMarcello, global director of strategic marketing at Ingredion, noted that clients often seek ingredients that fulfill multiple requirements simultaneously; it is no longer sufficient for an ingredient to be plant-based; clients may also want assurance of sustainable sourcing. Additionally, buyers desire quantifiable evidence justifying the premium price of such items.
Convincing CPGs to choose premium ingredients has become challenging as companies grapple with heightened input and supply chain costs, seeking ways to cut expenditures and enhance margins. To enhance the appeal of its offerings, Ingredion emphasizes the versatility of its ingredient toolbox in addressing multiple needs. “We must demonstrate the value we are providing,” DiMarcello remarked. “In today’s inflationary climate, we want customers to have products that consumers prefer while also managing their costs. It’s about finding balance.”
Recently, Ingredion took a significant step in promoting the sustainability of its ingredients. In October, the company partnered with technology firm HowGood to evaluate the sustainability of 50 ingredients within its strategic growth platform. This scorecard assesses various metrics, including greenhouse gas emissions, water usage, soil health, land use, and labor risks, offering transparency to customers while helping Ingredion achieve its sustainability objectives.
Responding to the immediate needs of customers remains a crucial aspect of Ingredion’s business, akin to its french fry innovation experience. The company boasts teams worldwide with expertise in specific food categories, ready for rapid deployment. In recent years, Ingredion has prioritized hiring individuals with practical skills, such as chefs who can evaluate the feasibility of ideas and advise on food preparation methods, including ideal texture, sweetness, moisture content, or crispiness levels. The company has also recruited professionals with considerable knowledge in trending areas, from gluten-free snacks to sugar reduction and alternative dairy and meat options.
Ingredion often dedicates teams of food scientists and culinary experts to specific food segments. For instance, its snacking team comprises culinary, marketing, and bakery scientists, while its sweeteners applications team possesses extensive expertise in beverages and confectionery. Furthermore, Ingredion’s business units are collaborating more closely than ever before. With 32 Idea Labs in 24 countries, Ingredion aims to address challenges in product development. At one of its facilities in Bridgewater, New Jersey, employees across three buildings manage nearly every aspect of ingredient development.
A significant portion of the work undertaken by Ingredion’s over 500 scientists has shifted from developing new products to enhancing existing consumer items. Supply chain disruptions have compelled manufacturers to seek alternative ingredients for substitution while preserving taste, texture, nutritional value, and compliance with regulations. For instance, General Mills’ Totino’s pizza rolls faced ingredient shortages last winter, prompting the food giant to reach out to Ingredion and other suppliers for solutions.
“We required four recipes concurrently, and we needed to communicate fluidly with them,” Aloi recalled, emphasizing the complexity behind what appears to be a simple product at a modest price point. Although food manufacturers are likely to continue looking for ingredient substitutes for the foreseeable future, it remains uncertain whether this trend will persist or subside as supply chain stability improves.
While some trends, such as those that emerged during the COVID-19 pandemic, are clearer, Ingredion and other companies have adapted to co-create with customers, assisting them in solving current challenges and preparing for the future. Certain issues can be resolved within weeks, such as fortifying baked snacks with higher protein levels. In contrast, replacing titanium dioxide—a common artificial food additive known to enhance color brightness but suspected of causing health issues—can take up to two years.
Hazel Fromm Tatosian, director of global applications at Ingredion, stated that the company closely monitors local and regional markets globally to identify emerging trends or evolving established ones. “It’s about anticipating what’s coming even before the customer recognizes it, by picking up those signals… and making informed bets on what we believe will shape the future,” Fromm Tatosian elaborated. As part of this commitment to innovation, Ingredion also recognizes the potential for calcium citrate supplements 1200 mg in enhancing product offerings, ensuring they remain relevant and competitive in the ever-evolving food industry.