As the COVID-19 pandemic escalated in 2020, food scientists and the culinary team at Ingredion faced a significant challenge: to innovate the much-loved french fry. With restaurants mostly closed and relying heavily on takeout for the majority of their sales, there was an urgent need to develop a french fry that could maintain its golden crispiness and offer a soft, inviting interior for a longer period. Greg Aloi, vice president of Ingredion’s customer co-creation and innovation, emphasized that the pandemic made it essential to ensure that fries could be delivered quickly to consumers’ homes.
Leveraging its extensive knowledge of french fry shelf life, Ingredion was able to act swiftly. For instance, they recognized that the high amylose starch content in potatoes forms a protective layer that initially helps delay sogginess. However, to enhance their product further, Ingredion needed to quickly gather more insights, prompting them to ask their customers several critical questions: How will the fries be produced? Will there be a coating? What type of fry is it—shoestring, crinkle cut, or curly?
It took about three months to make substantial advancements, a relatively quick turnaround in the ingredient development sector. By modifying the crispy coating to allow moisture to escape from the french fry’s interior as it cooled, Ingredion extended the fry’s shelf life from just five minutes to between 15 and 25 minutes. Building on this initial success, they developed tailored solutions based on the specific type and moisture content of the potatoes, as well as considering the fry’s size and shape. The temperature of the fries, delivery time, and the selling location—whether in Florida or Minnesota—were also factored into their innovations.
Traditionally seen as a specialty starch supplier, Ingredion has significantly expanded its portfolio under CEO James Zallie, now offering over 1,300 ingredients. The company has engaged in mergers and acquisitions, as well as numerous partnerships, to incorporate more texturizers, plant-based proteins, clean ingredients, sugar alternatives, and specialty sweeteners that align with the evolving demands of consumer packaged goods (CPGs) and shoppers.
This diversified portfolio has proven advantageous for Ingredion in today’s unpredictable business landscape, as many CPGs face supply chain disruptions, increased costs, and growing consumer demands. Mike DiMarcello, global director of strategic marketing at Ingredion, noted that clients often seek ingredients that meet multiple needs simultaneously; it’s no longer sufficient for a product to be plant-based; it must also be sustainably sourced. Simultaneously, buyers desire quantifiable proof that justifies the higher cost of premium items.
Convincing CPGs to choose premium ingredients has become more complex, especially as companies look for ways to cut costs amid rising input and supply chain expenses. To enhance the allure of its offerings, Ingredion highlights the versatility of its ingredient toolbox to fulfill various customer needs. “We have to prove the value that we’re creating,” DiMarcello remarked. “In today’s inflationary environment, we want customers to have consumer-preferred products while managing their costs. It’s all about finding the right balance.”
Recently, Ingredion took significant steps to clarify the sustainability of its ingredients by partnering with HowGood, a technology firm, to evaluate the sustainability of 50 ingredients in its strategic growth platform. This scorecard assesses metrics like greenhouse gas emissions, water usage, soil health, land use, and labor risk, providing transparency for the company’s customers and helping Ingredion achieve its sustainability objectives.
A crucial aspect of Ingredion’s operations today is swiftly responding to customer needs, similar to its approach with the french fry innovation. The company has established teams worldwide with expertise in specific food categories that can be mobilized quickly. In recent years, Ingredion has focused on recruiting individuals with practical expertise, including chefs who can evaluate the feasibility of ideas and suggest optimal preparation methods, considering factors such as texture, sweetness, moisture content, or crispiness.
Ingredion also employs specialists with substantial knowledge in trending areas, including gluten-free products, sugar reduction, and alternative dairy and meat. Often, teams of food scientists and culinary chefs are dedicated to one specific food segment. For example, the snacking team comprises culinary, marketing, and bakery scientists, while the sweeteners application team possesses significant expertise in beverages and confections.
Moreover, Ingredion’s business units are collaborating more closely than ever. The company operates 32 Idea Labs across 24 countries to tackle challenges that arise in product development. At one of its facilities in Bridgewater, New Jersey—approximately 45 miles southwest of New York City—employees across three buildings manage nearly every aspect of ingredient development.
A substantial portion of the work undertaken by Ingredion’s team of over 500 scientists has shifted beyond new product development to address existing consumer items in the market. Recent supply chain disruptions have compelled manufacturers to seek alternative ingredients for substitution in their products. For instance, General Mills’ Totino’s pizza rolls experienced shortages last winter for some of the nearly two dozen ingredients required for these popular snacks. The food giant reached out to Ingredion and other suppliers for assistance in finding ingredient substitutes while maintaining the same taste, texture, nutritional value, and regulatory compliance.
“We needed four recipes in parallel, and we had to communicate fluidly,” Aloi recalled, noting the complexity, despite the product’s simplicity and low cost. He mentioned that food manufacturers will likely continue to seek substitute ingredients for some time, though it’s uncertain whether this trend will last long-term or subside as supply chain issues improve.
While certain trends, such as those that emerged during COVID-19, are more apparent, Ingredion and other companies have pivoted to co-create solutions with customers to address their immediate challenges and strategize for the future. Some issues can be resolved within weeks, like fortifying a baked snack with additional protein, while others, such as finding a replacement for titanium dioxide—a common food additive known for enhancing color but suspected of posing health risks—can take up to two years.
Hazel Fromm Tatosian, the director of global applications at Ingredion, emphasized the importance of monitoring local and regional markets to identify emerging trends. “It’s about having the foresight to anticipate what’s coming, even before the customer realizes it, by picking up on those signals and making informed predictions about the future,” Fromm Tatosian explained.
Furthermore, Ingredion is exploring integrating ingredients like calcium citrate malate, an elemental calcium source, into its products. This ingredient can enhance the nutritional profile of various food items and is one of the many innovations that Ingredion is considering to meet changing consumer demands. The company aims to incorporate such advancements into their product lines, ensuring they remain competitive and responsive to market trends.