Ever wondered how we choose what flavor to launch next? Come behind the scenes to see what’s involved when we develop new flavors.
First of all, our New Product Development (NPD) team get together and discuss lots of exciting flavor options. Of course, our ideas adapt and change as they are developed, but this first step is critical in the development process. These ideas could include anything from gaps in our flavor range, popular flavor trends in the market, and most importantly, feedback from our Hueligans.
The Huel forum is a great place filled with your insights and new flavor ideas. We use your feedback as much as possible to optimize the flavor of existing products or launch new ones.
When developing a new product, we keep an eye on the latest flavor trends and on what is popular with consumers. We also consider many other aspects. For example, sustainability is always on our minds, as well as the different taste of our customers all around the world.
There are many companies that produce flavors (called flavor houses, or flavor manufacturers), so when choosing the right one we always consider the quality of the facility, of their processes, and of course of the product. Above all, we make sure they support our mission of making nutritionally complete, convenient, affordable food, with minimal impact on animals and the environment.
Creating flavors is a complex process. There are over 25,000 flavor molecules recorded in the flavor database that represent specific tastes and volatiles. Of these, 2,254 are derived from 936 natural ingredients and are separated into 34 categories. Understanding all of these and how they mix with each other takes a specific kind of expertise and years of experience. The flavor houses we work with have the very best flavor chemists with the right skill set to combine this knowledge with a new challenge such as Huel.
Flavor houses initially produce flavor in a liquid form. However, when it comes to creating dry products such as our Huel Powder, we need the flavors to be in a dry format.
Spray-drying is the most commonly used technique for the production of dry flavorings. During the spray-drying process, an aqueous solution made up of water, a carrier (e.g. maltodextrin and gum arabic), and liquid flavor, are dried into fine particles through a stream of extremely hot air which traps volatile flavor constituents inside the droplets (‘volatiles’ are substances that evaporate quickly in normal temperatures). Gum arabic is commonly used in combination with other hydrocolloids (substances which form a gel in the presence of water) such as maltodextrin, as a carrier in the encapsulation of flavors.
This process allows the flavors to be handled and applied more easily, and makes the flavor more stable to oxidation. The process of encapsulation allows for a high retention of the volatile flavor components, usually more than 80%.
The most important part of developing our new flavors is selecting ingredients that provide the right nutrition. As you can imagine, these natural ingredients come with some interesting sensory attributes, such as green notes (freshness), earthiness, astringency (dryness/chalkiness) and bitterness. Taste is subjective and people react to these sensory attributes differently. So developing a new flavor is a balancing act: we always try to develop products that can be enjoyed by all our Hueligans.
The flavor of our natural ingredients (oats, peas, rice, coconut, flaxseed, etc.) is subject to small changes due to natural variances as well as growing, harvest, and storage conditions. These tiny variations can have an impact on the overall flavor profile of our products which is why we have strict quality controls and checks in place to make sure the flavor of our products is just right.
We’ve outlined the production considerations and flavor profiles of each of our products below:
The fine tuning of the flavors can take up to a few months, so it is a very delicate process. This includes adjusting the amount of flavor and flavor enhancements until we get the right flavor.
We use sucralose in our flavored Powder (not Unflavored & Unsweetened) and Ready-to-drink products. There are limits on how much sucralose should be put into a product per recommended portion, and even at 2,000kcal (the amount at which Huel products are nutritionally complete) our products are well below these limits.
Our product development team are continuously working towards lowering the amount of sucralose in the product range, however, extensive development has so far shown that natural sweeteners do not provide the same flavor or sweetness profiles as sucralose.
Read more in our Guide to Sucralose.
Salt is a useful tool in the development of flavors as it can help to bring out certain flavor components of a blend, and can increase the perception of flavors that you find pleasant.
The inclusion of salt can also mask unpleasant flavors, such as bitterness. However, we are always careful not to use too much salt as it will influence the nutritional profile of our products.
We developed the range of Huel Flavor Boosts so you are able to customize the flavor of your Huel Powder and have a great Huel experience.
Flavor Boosts consist of a carefully balanced blend of natural flavoring with natural sweetener (stevia). Although these have been designed to be added to Huel at about 2%, the magic of these products is that you can add as little, or as much as you like. With the addition of stevia, the flavors add not only a boost of new flavor to Huel Powder, but also extra sweetness.
Once our product developers feel they have created a great flavor, they share it with the rest of the team for testing (our favorite part). They conduct various taste tests including triangle tests, blind tastings, and Hueligan insights. These tests objectively analyze foods for taste, smell, appearance, and texture.
A triangle test is a type of ‘difference’ test that asks if there are sensory differences between two products. This test is particularly useful when a flavor is in the larger-scale trial, i.e. running the powder through a full manufacture process. This allows us to check if there are any batch-to-batch variances, so we carry them out in all cases when recipes are scaled up to ensure consistency.
In a blind taste test, the sense of sight is taken away from tasters, which reduces bias from seeing the product. This is an important test to conduct when looking at flavor alone by isolating the senses.
Taking all these steps into account, launching a new flavor in our existing product range can take up to 26 weeks. If we’re developing a brand new product, the process may be extended as the NPD team need to understand how the flavor will interact with the new product formula.
Once the new flavor is approved by the wider team, we sometimes send the product to a small number of regular Hueligans to provide pre-launch feedback. When we officially launch to market, we eagerly await your feedback via the Huel forum and social media platforms. This helps us to create the best possible products for our Hueligans.
We welcome your feedback, so if you have comments about our flavors, please get in touch.
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