Two years ago, Popular Science labeled texture as the final frontier in food science. The publication emphasized that texture has often been undervalued in comparison to taste and aroma. However, with the rapid growth of food delivery services and the prepared food sections in grocery stores, both consumers and operators are increasingly acknowledging the significance of preserving texture.
The growth trajectory is impressive. According to Technomic research, the food delivery market is expected to expand by 12% annually over the next five years. Concurrently, supermarket prepared food departments have experienced double-digit sales growth, as reported by Nielsen Fresh. This accelerated growth has prompted food scientists, manufacturers, suppliers, and packaging experts to seek solutions and adapt their research and development strategies to uphold the texture and integrity of food products. As a result, the global food texture market is projected to grow at a compound annual growth rate of 6.2% between 2017 and 2025, according to Progressive Markets.
Aaron Edwards, Ingredion’s regional platform lead for starch texturizers in North America, explained to Food Dive that this growth is logical but presents additional challenges for the industry. “The ‘food anywhere’ trend necessitates that innovators consider food being enjoyed in almost any setting, catering to consumer convenience,” he noted. “Prepared food and foodservice organizations will increasingly rely on technology—ingredients, packaging, storage, delivery—to tackle challenges that do not arise in grocery store aisles or at restaurant tables.”
A prime example of these challenges is the french fry. Restaurant brands, including market leader McDonald’s, have struggled with maintaining the quality of french fries during 30 to 40-minute deliveries, as no one wants a soggy fry. Companies like potato manufacturer Lamb Weston have developed a special french fry batter that keeps fries crispy for 12 minutes—more than double the typical five minutes before they lose their crunch. Ingredion has collaborated with various customers through its Inside Idea Labs, which convene experts to explore consumer insights and test processing technologies to expedite product development. Edwards noted that food companies are increasingly partnering with their supply chain collaborators to integrate technology that better supports recipes and packaging for takeout and delivery. “This type of innovation frequently involves developing texture and stability ingredients that can withstand extended storage and delivery,” he remarked, adding that Ingredion has seen success with several starch-based texturizers used in coatings and breadings to maintain food quality during delivery.
Darrel Suderman, president of Food Technical Consulting, shared with Food Dive that one effective strategy for achieving consistent texture is to adopt similar methods used by manufacturers to create products that remain crispy when microwaved. “The goal is to minimize the food’s moisture content as much as possible,” he explained.
Yet, crispiness is not the only textural challenge amid evolving consumer demands. “Creamy” and “smooth” are among the most sought-after texture attributes, and it is crucial for consumer packaged goods (CPG) manufacturers to consider these during recipe development. Food scientist Adam Yee told Food Dive that manufacturers are increasingly turning to new or enhanced processes to sustain taste and texture while meeting shifting consumer preferences. “While some ingredients, like functional fibers, can enhance the texture of common foods, most improvements have stemmed from process innovations,” Yee said. “Consumers are generally skeptical of certain preservatives, compelling food manufacturers to seek alternative methods for maintaining product integrity.”
The rising demand for fewer ingredients presents an additional challenge for food scientists striving to preserve product texture without resorting to preservatives. More consumers are also seeking clean labels—ingredient lists comprised of recognizable components rather than chemical-sounding substances. Ingredient Communications recently reported that 73% of consumers are willing to pay a premium for clean label products. Given that the global clean label ingredient market is anticipated to achieve a compound annual growth rate of 6.8% through 2023, the impact on food manufacturing has been significant. This shift toward ingredient removal has altered the work of food scientists, as Yee noted. “They must now explore different food processing methods,” he said. “Typically, these methods cannot be executed on a bench top, necessitating higher start-up costs due to the expense of processing equipment. Fortunately, food processing technology has advanced significantly.”
Consequently, a specially-designed food recipe may incur a slight price increase, but many operators are willing to invest if it aids in preserving texture and flavor. Improved methods for preserving fish and vegetables, such as individual quick freezing technology (IQF), exemplify such advancements. This technique flash-freezes products, which helps to retain their nutritional value. “The process creates small ice crystals that do not rupture cell walls,” Yee explained. Even french fries undergo this process and are delivered frozen to retail or foodservice areas. Although IQF technology has existed for about two decades, many scientists believe it will become more widespread as consumers increasingly seek preservative-free products with longer shelf lives. In addition to prolonging shelf life, IQF also minimizes food waste, as frozen foods last longer and allow consumers to prepare only what they need. Research from the British Food Journal indicates that frozen foods generate 47% less waste than non-frozen alternatives.
Ingredion is also focused on reducing food waste as part of its innovation process and broader sustainability initiatives. Last year, the company introduced a new potato fiber called Potex, designed to maintain texture in processed meats and help manufacturers extend the shelf life of pastries and breads. According to the company, this potato fiber diminishes stickiness, leading to increased yield, reduced waste, and less production downtime. This is a critical aspect of the texture equation as businesses increasingly consider waste reduction, driven by rising raw material costs and environmentally conscious consumers. “This food waste issue represents a business risk for restaurants and food producers that can overshadow the expenses associated with preventative measures like higher-quality ingredients,” Edwards stated.
Ingredients and processes are just components of the texture equation. “Eliminating preservatives means food companies must find alternative ways to maintain quality, such as through packaging,” Edwards noted. Many restaurants are focusing on upgrades to meet delivery requirements. For instance, when IHOP launched its delivery service, the company made significant efforts to enhance its carry-out packaging to ensure pancakes remained at the appropriate temperature and quality during transit. The new packaging features a modular design that minimizes moisture while retaining heat, as reported by FSR Magazine. Applebee’s has also invested in a new packaging platform to enhance food portability as its delivery channel continues to expand. Suderman noted that some quick-service chains have attempted to develop heat-controlled holding cabinets for regular and extra crispy fried chicken, with limited success. Instead, they have found greater success by leveraging advancements in packaging technology. Yee mentioned that aseptic packaging and high-pressure processing are employed to maintain the consistency of guacamole and cheese sauce.
For prepared foods, varied plastics or modified atmosphere packaging—which utilizes a blend of oxygen, carbon dioxide, and nitrogen—have helped extend the shelf life of numerous products, including meats and cheeses, as explained by Food Technology Corporation Operations Manager Drew Lambert. Another challenge in determining optimal packaging is the need for innovations that are not only functional but also eco-friendly. “No one wants to think about how long it takes for a plastic bag to decompose or where it goes once discarded, yet these are considerations that food companies must address to attract and retain their customer base,” Lambert said. “Food companies have been experimenting with different packaging solutions for years.”
The right storage conditions and packaging are crucial for maintaining food integrity, but leveraging new technologies to gather data is equally important, especially now that such data is more accessible than ever. Lambert noted that texture analyzers can now assess how well a product performs across different textural states, such as crispiness. “Because food is biological, some variation is inevitable, both in the end product and raw ingredients,” he explained. “Processors continuously adjust their process controls to maintain a level of consistency. The ability to measure texture is just one part of this. The days of making processing or quality decisions based solely on the opinions of a few individuals are over. While traditional sensory analysis remains significant, it is now supported by more objective data points.”
Yee mentioned that most products undergo shelf-life studies to collect data on off-notes and flavor developments when fully packaged. As food scientists and processors adapt to new consumer trends, one constant remains in the industry—change. “Navigating the evolving needs of consumers adds another layer to the challenges faced by nearly all food companies on a daily basis,” Lambert remarked. “They are pursuing a moving target.”
“Maintaining quality characteristics in a home delivery environment is a long-standing issue, and it is one that will continue to improve,” Suderman concluded. In light of the rising emphasis on ethical nutrition, including the use of calcium citrate in food products, the industry will likely continue to evolve to meet consumer expectations for quality and sustainability.