“Pull [sugar] out, like we do, and you have to re-solve viscosity, mouthfeel and shelf stability all at once,” he explains. “Erythritol doesn’t behave like sucrose in a kettle; it crystallizes differently, hydrates at a different rate and can throw off pectin activation entirely.”

Furthermore, the interaction between pectin, acid and the sugar substitute requires diligence in blending, and is “the single hardest thing to get right when reformulating a classic recipe without sugar,” Stefansson says. “Get the sequence or timing wrong and you get weak-set jam, syneresis (weeping) or over-set ‘rubbery’ texture.”

A ‘natural’ challenge

In the meat and poultry industry, processors also need to manage the natural variation of raw product in order to deliver a consistent finished product, says Rick Getman, vice president of pork operations for Perdue Specialty Meats.

“Meat is not a standardized raw material,” he explains. “Fat content, temperature, moisture and other characteristics can vary from batch to batch, but consumers rightly expect the product to perform and taste great every time they purchase it.”

Processors working with fruits and vegetables understand this challenge as well, as real fruit isn’t uniform from piece to piece either, Stefansson adds.

“Brix, pH and pectin content shift with season, ripeness and even the specific farm lot,” he says. “Processes optimized for one batch of strawberries can get a completely different set of behavior three weeks later.”

Add to that the complexity of many companies’ product portfolios in some of these categories, and things get even more chaotic to manage. “A facility may produce multiple lean-to-fat ratios, species, flavor profiles, package sizes and customer specifications in the same day,” Getman adds. “That creates challenges related to scheduling, changeovers, allergen controls, sanitation and ensuring every formulation is connected to the correct product and label.”

For Perdue Specialty Meats brands such as Niman Ranch and Coleman All Natural Meats, consistency expectations are even higher, because “consumers increasingly expect processors to deliver both exceptional eating quality and production practices they can feel good about,” he explains.

“Ultimately, consumers don't necessarily think about mixing and blending — but they absolutely notice when a product isn't consistent,” Getman says. “Every operational decision we make ultimately shows up in the eating experience and determines whether consumers trust our brands enough to buy them again.”

Ramani and PIM Brands think similarly about delivering that consistency when it comes to their products as well.

“It may sound simple, but delivering the same great experience every time requires relentless attention to detail across ingredients, processes and, in particular, quality controls,” Ramani says. “Those details matter more than many realize because our consumers expect Welch's Fruit Snacks — and all our products — to taste and perform the same way every time they open a pouch.”

Blending R&D with operations

Getman says achieving the consistency demanded by consumers “starts long before the product reaches the mixing room — it begins with disciplined sourcing, well-controlled manufacturing processes and a culture that pays attention to the details every day.”

Those details start with choosing the right ingredients to maximize performance, says Chef Andrew Hunter, who leads R&D and product development for Wolfgang Puck Worldwide, Niman Ranch, Kikkoman and The Mushroom Council. Over the years, the rise in sausage products that include cheese in the blend has risen quite a bit, and Hunter uses it as the perfect example of proper sourcing through R&D work.

“Processors who want to put cheese in their sausage or burgers need to look for cheeses that are specifically designed with a very high melting point,” he says. “Because what you don't want is for the cheese to just weep out of the sausage or the burger while it's cooking.”

In companies with open channels of communication and collaboration, product developers, chefs and culinarians typically aren’t aiming to overturn the entire process, although some patience is required, says Hunter.

“The goal is always to work within the capabilities of the existing processing lines and protocols,” he explains. “But there’s no question that it’s a process with a lot of trial and error.”

Once the ingredients reach the mixing operation, everything -- from particle size to grinding sequence, mixing speed and time to fill levels -- needs to be on target. Fortunately, technology and innovation have kept pace.

Modern mixing and blending systems provide more precise control over temperature, mixing time, equipment speed, ingredient addition and batch weights, while recipe-management systems help ensure use of the correct formulation and sequence. For baking operations, proper ingredient measurement, using ingredient weight rather than volume, remains critical to success from plant to plant, explains Claire Zelenka, team leader-technical counselor for Rich Products.

“Volume measurements can introduce significant variation from baker to baker, which may lead to inconsistencies in production and finished products,” she says. “Using weight measurements provides greater accuracy and helps ensure a more consistent outcome across batches, regardless of who is preparing the recipe.”

Getman agrees that accurate weighing and ingredient staging are critical no matter the mixture, as even a minor measurement error can have a major effect on flavor, appearance or product performance. Additional innovation in data collection offers greater visibility into yields, downtime, product variation and overall process performance in mixing and blending operations. However, equipment still needs to be in top operating condition, and changeovers and sanitation need to be performed properly.

“Ultimately, the most meaningful innovation is technology that helps people work more efficiently, make better decisions and control the process more precisely,” Getman says. “The goal isn't simply to automate, it's to deliver safer, more consistent, higher-quality products while giving customers and consumers the variety, convenience and premium experience they increasingly expect.”