For many of us, the term “baked” invokes imagery of some of the most appetizing finished goods – pies, cakes, muffins, cookies, breads, pastries, etc.
With the popularity of nostalgic foods like these, today’s consumers are looking for flavors and formats that bring back the warmth and comfort of simpler times.
That’s why we created our Baked Portfolio, a collection of dried powders made from whole sweet potato, pumpkin, or apple. These powders have special features that are created through their unique drying process, which sets them apart from other dried products, such as their air-dried counterparts.
What are the unique features of our baked products? How are they created? And what does that mean for product developers looking to innovate with these ingredients?
We asked these questions plus more to culinary expert Charolette Browder. Charolette is a Certified Research Chef with a bachelor’s degree in culinary science from the Culinary Institute of America. She has multiple years of experience with food manufacturing and processing and is currently the Manager of Culinary Innovation and Applications at Van Drunen Farms.
She agreed to answer some of our questions about the Baked Portfolio. Her answers reveal some of the unique qualities that define these products and offer valuable insight into their diverse application possibilities.
Q: Can you describe the process for creating our baked powders?
A: Our baked powders are created by pureeing fresh, whole fruits, vegetables and/or grains, then cooking them in large tanks and pumping the cooked puree onto our dryers in a thin layer. This creates a dried flake that can be ground into a powder.
The finished baked product can either be 100% dried material from the original fresh item or it can have a carrier added, depending on the customer’s needs.
Q: What are some of the features of baked products that make them useful in applications?
A: Some of the key features of our baked powders are:
- They are very versatile and can serve multiple functions
- They rehydrate quickly due to the unique drying process
- They can thicken in cold water because all the starches are cooked and therefore pregelatinized
- They go through a validated kill step
- Flakes are possible, allowing for more visual identification in dry applications
- They have a cooked flavor and deep color – meaning they don’t have the raw flavor or dull color commonly found in dried alternatives – due to the Maillard reactions and caramelization that occurs during the drying process
Q: Earlier, you mentioned that carriers can be added to our baked powders. Can you expand on that and why it matters?
A: Sure! The unique drying process allows us to use different carriers to influence viscosities. For example, when baked powders or flakes are rehydrated, non-modified starch carriers like corn, rice, or tapioca increase viscosities while partially hydrolyzed starch carriers like maltodextrin have minimal effect on viscosity. We can adjust the type of carrier as well as the inclusion rate to manipulate the viscosities of rehydrated baked items.
We can also customize carrier options depending on our customers’ needs. An oat flour carrier can be used in a product that is oat based, or a bean or lentil flour carrier can be added for extra protein.
Baked ingredients without any carriers added have their own benefits. Along with shorter, simpler labels, they better maintain the characteristics of the original item. This makes our baked powders great alternatives to purees, which are not only typically more expensive to ship (due to water content), but also often lack the complex depth of flavor and cooked notes of our baked powders.
Q: What are some other ways baked powders offer application flexibility and opportunity?
A: One prime application opportunity for a baked powder replacement is anything that would typically use a puree or mash – especially items that are sold in a dry format. For example, adding our baked pumpkin powder to a dry pumpkin bread mix allows the end user to skip the can of pumpkin puree without skipping the use of real, cooked pumpkin – not just pumpkin flavors and colors. This also provides the flexibility to create line extensions and alternate formats more easily.
Another way our baked powders can be used is as a driver of sweetness without additional sweeteners. For example, apple powder could replace sugar or sugar alternatives to boost sweet flavors.
And one of the biggest opportunities for our customers has to be the potential for TruServ® verified serving claims. To me, getting the functionality benefits I mentioned above and a fruit or vegetable serving claim on the front of your package seems like a win-win.
Q: What are some of the common applications for baked powders?
A: Traditionally, flakes and powders that have gone through the drum-drying process are used in applications like:
- Baby foods and other ready-to-eat breakfast cereals
- Snack and protein bars
- Fully baked items and dry baking mixes
- Instant mashed potatoes
- Dry soup mixes
- Instant and cold-water hydrating items (puddings and protein shakes)
- And others
There are numerous other uses for drum-dried powders and flakes. For example, this process is how fish food flakes are made!
Q: You mentioned that baked powders are great replacements for traditional purees. Can you talk more about how they can be used in items where moisture control is a concern?
A: Sure – items that require more control over moisture are great candidates for baked powders. A lot of purees aren’t standardized to a particular moisture content level, especially purees from different manufacturers, even with the same type of raw material. Using a baked powder allows you to control water additions and provides a consistent moisture level in the product from lot to lot.
They are also great in applications where moisture is later removed – i.e. cooked, baked, fried, or other heat processes that remove water after being mixed. Our baked powders have a very low moisture content, which helps expedite the moisture removal process.
Q: Given the features and benefits of baked powders and flakes, are there any unexpected applications for these ingredients? If so, what are your favorites?
A: Due to the product’s quick rehydration ability, our baked powders can be easily included in items such as instant oatmeals and porridges, and ready-to-mix beverages. They are also great for cold processed items like puddings, yogurts, and ice creams.
For low-moisture items that are shelf stable – crackers, chips, dried noodles, cake/pastry/bread mixes – the baked powders can help add a more vibrant color and deep flavor. These applications are also great for adding serving claims.
Some of my favorite uses are the more intriguing and unique applications that we have tried, such as opportunities for topical applications (seasonings, icings, frostings, etc.) and confections (candies, chocolates, taffies, etc.).
Q: Are there any other important points about using baked powders that product developers should know?
A: If there are any takeaways for a product developer, it’s these:
- Our baked powders are incredibly versatile and very cost-effective.
- They help you create premium, elevated products at reasonable costs.
- They do much of the work for you (pre-cooked, pre-browned, and pre-gelatinized).
- They have more concentrated flavors than purees and don’t taste raw like many of their dried counterparts.
Ready to taste the difference for yourself?
Sign Up for the Baked Challenge to receive a FREE kit that includes a baked product from our portfolio and an air-dried alternative to compare it with.