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Swiss lab and production specialists BUCHI works with major brands such as Nestlé and Prima, as well as small and medium-sized enterprises like Kwong Cheong Thye, a Singapore-based condiment manufacturer.
These firms are leading the way in using lab-grade tools in their production lines.
“With innovative developments in the F&B scene, the line between the kitchen and the laboratory has been blurred. Manufacturers are increasingly adopting scientific tools like the rotary evaporator and freeze dryer to create new flavours and textures,” said Qing Qing Dai, general manager at BUCHI. She was speaking to FoodNavigator-Asia at the Speciality Food & Drinks Asia (SFDA) 2024, held at the Sands Expo & Convention Centre in Singapore from 26 to 28 June.
Flavour, safety, and quality
Traditionally used for distilling solvents, the rotary evaporator has found its place in food production, where it can concentrate ingredients like infused alcohols, non-alcoholic beverages, or soups. This not only helps brands develop innovative products, but also improves safety and quality.
There are several key uses of a rotary evaporator.
Firstly, it delivers concentrated flavours from herbs, fruits, or any other ingredients infused into a beverage. By removing water and other impurities, the distillation process captures the pure essence of the infusion, resulting in a more potent and refined flavour.
Distilling a beverage also ensures a consistent flavour across batches.
This enhances overall quality and safety.
Most importantly, it can extend shelf life by removing excess water, reducing the risk of microbial growth or spoilage.
Also, manufacturers can customise drinks by controlling the strength of each ingredient.
For example, by adjusting factors like temperature and infusion time, manufacturers can fine-tune the intensity and balance of specific ingredients, resulting in unique, tailored flavour profiles. This flexibility allows for the creation of distinctive spirits and products that cater to specific tastes.
The freeze dryer, while not new in food production, is also increasingly used to add flavour, texture and nutrition.
It was originally developed for preserving pharmaceuticals and biological materials.
The freeze drying technology is instrumental in preserving the flavour and structure of ingredients during the drying process.
For instance, the low temperature is effective in producing freeze-dried fruits and herbs without loss of nutrients. These are used by food brands to add varied textures and flavours to their products – something that today’s health-conscious consumers appreciate.
“Food brands are now blending tradition with science,” Dai explained, “using advanced tools like freeze dryers to create distinct products that appeal to modern consumers.”
But it’s not just about flavour and texture. These tools also help manufacturers streamline production processes.
Automation and digitalisation
As brands strive to meet evolving consumer demands, automation and digitalisation have become essential in streamlining operations and ensuring consistent quality.
“[This trend] is driven in part by the ongoing shortage of manpower in the industry. There is a need to adapt quickly to maintain a competitive edge in a rapidly changing market,” said Dai.
Near-infrared (NIR) technology, for example, enhances efficiency by allowing manufacturers to continuously monitor production processes instead of relying on post-production testing.
It works by passing NIR light through a sample and measuring how much light is absorbed by different components within the material, such as moisture, fat, protein, and sugar. This non-destructive method provides rapid, accurate insights into the composition of food products without the need for extensive sample preparation or laboratory testing.
One of the key advantages of NIR technology is its ability to offer real-time data during food production.
As materials pass through the production line, NIR sensors can continuously monitor critical parameters, allowing manufacturers to detect and correct issues immediately. This reduces waste, improves efficiency, and ensures that products consistently meet quality standards.
For example, in dairy processing, NIR can be used to monitor fat and protein levels in milk, ensuring consistency across batches.
The X-Sential™ process sensor, a recent advancement in NIR technology, enhances this capability even further. It is designed specifically for food producers, providing precise, real-time information about raw materials and in-process products. With its ability to analyse multiple samples quickly and accurately, the X-Sential™ process sensor helps manufacturers streamline operations, optimise resource use, and reduce costs.
By integrating NIR into their production lines, food companies can benefit from faster decision-making and improved control over their processes. This technology also enables better traceability, as detailed records of each production batch can be stored and used for compliance with regulatory standards.
In an industry where quality control and efficiency are critical, NIR technology is becoming an essential tool for staying competitive and meeting evolving consumer expectations.
“As consumer preferences continue to evolve, the F&B industry is being reshaped, with brands increasingly adopting new technologies to enhance the sensory experience of food and beverages,” said Dai.