Emulsifiers provide functionality and process stability in a wide range of baked goods including donuts, cakes, muffins and bread.

Operational disruption
A major role for emulsifiers is the ability to make doughs and batters friendly to commercial processing. One of the challenges in removing phos from these ingredients is losing some of that operational ease-of-use, whether that’s the handling of the raw ingredient or reduced processability of the dough or batter.  

Minimizing operational disruptions as bakers made the switch to non-pho emulsifiers was a priority for Corbion. Not only was Ensemble designed with this in mind, but SweetPro for sweet goods also was created to accommodate commercial processing.

“SweetPro non-pho emulsifiers are specially designed to help boost product tolerance against numerous production and distribution variables, giving sweet baked goods manufacturers the confidence to deliver quality products all year long,” Mr. Robertson said. 

Dispersible monoglycerides, mostly used in bread-making or donut mix applications, can see issues in the mixer if the melt point is exceeded. If that happens, the emulsifier will smear out and coat the blades and the mixer, which requires downtime to clean, Mr. Cottrell said. Kerry’s Myvatex Mightysoft line helps prevent these issues in donut mix applications.

Ingredient handling can also be an issue, particularly for powdered dispersible monoglycerides.

“The conveyance equipment used for dosing emulsifiers in bakeries was designed for the robust conventional powders made using phos,” Mr. Cottrell said. “Warmer temperatures, rate of shear and physical abuse of the non-pho powders can cause clogging, clumping and build-up in augers, vane pumps or elbows of powder handling systems.”

With issues like these, bakeries turn to manually handling and scaling emulsifiers, which adds to cost, waste and safety concerns. Kerry has several new products with powders that handle more like flour or high melt point fat powders.