Swiss margarine producer Grüninger has developed technology to produce palm-free, vegan and vegetarian margarines that mask any off-notes. 

The three steps of Grüninger’s flavoring process complement each other and offer many possibilities for individualization, Michel Burla, managing director of Grüninger, tells FoodIngredientsFirst. 

“First, a natural antioxidant ensures heat stability so that no off-flavors form during high-temperature processing. Subsequently, undesirable fat and oil characteristics are masked. Off-notes, such as the ‘green’ aftertaste that’s often associated with canola in palm-oil-free products, are neutralized,” he explains. 

The subsequently stabilized and neutralized oils, fats, or emulsions can then be prepared and are ready to absorb the desired top note.

Instead of using dominant sensory molecules such as vanillin or diacetyl that tend to disguise off-notes, Grüninger product developers selec specific masking flavors for the respective application from a library of flavors. 

In addition to natural butter and vanilla notes, possible flavors include creamy-milky, fresh-sour and/or neutral-slightly sweet, as well as lightly roasted, nutty notes. 

Application variations
Depending on the target market and application, very different flavorings may be required, Burla flags. 

“Flavor release varies according to the application – spreading versus baking, for example – and these differences influence the choice and dosage of top notes, which is why the flavor matrix is composed specifically for each application,” he explains. 

“Using this procedure, we can meet the requirements of specific demands and any new trends we encounter.”

At the center of the process is a natural rosemary extract-derived antioxidant that extends the products’ shelf life and increases heat stability during baking. 

Employed to overcome common hurdles that arise when replacing solid palm fat with alternative oils, the neutralized fats are subsequently custom-flavored to match specific applications. 

In addition to stabilizing the flavor of margarines and vegetable and animal oils and fats, a key benefit is an optimized mouthfeel. 

Fats in the spotlight
Among both consumers and industry, healthy vegetable fats are currently in high demand. At the same time, the acceptability of products containing palm oil is declining. 

However, widespread palm alternatives such as rapeseed oil bring notable challenges, including intense organoleptic properties, high oxidation potential and individual processing requirements. 

Grüninger’s new process is of particular interest to bakery and confectionery manufacturers because it offers advantages from factory to fork. 

First, any oxidation-labile fatty acids are stabilized during refining and crystallization with the help of a natural antioxidant. 

This both significantly extends the shelf life of the end product and prevents heat-induced off-flavors that can arise during baking. 

It’s also possible to modify the taste of soft margarines, sandwich spreads and a wide range of special fats for industrial or commercial bakers.

The products flavored with the help of the new process reconcile consumer wishes with industry requirements: “Fat is one of the most important flavor carriers, which has a decisive influence on the end products market success,” says Burla. 

“In addition to flavoring, we rely on cooling drum technology to optimize the plasticity of the products, which is especially important when dispensing with structure-giving solid palm fat.”

Formulation challenges
The range of products used in baked goods, for example, is vast, and whether it’s for puff pastry, shortcrust or other doughs, the fat must fit the application exactly. 

The environmental sustainability trend is “almost ubiquitous,” notes Burla, hinting that organic products are still on the rise. 

“We also see a growing need to replac palm oil with other oil components. This, in turn, means we have to adapt flavor profiles to avoid undesirable off-notes. Customers want an ideal fit in terms of sustainability, processing procedure and, obviously, taste.”

Commenting on formulation challenges, Burla says that changing a margarine or fat blend recipe to optimize production can affect both its taste and other properties, especially if a higher proportion of rapeseed or linseed oil is used instead of tropical fats. 

“They are considered healthy but often have intense organoleptic properties, a high oxidation potential and/or other processing requirements. In all cases, our flavoring process allows for an optimal and tailor-made product,” he concludes.