Food formulation is the process of developing or designing food products with added functionality and hence is a vital step in product development. A judicious selection of ingredients with appropriate use of technology, and production processes are of paramount importance as consumers prefer a final product based on the tangible and intangible benefits they offer. The food recipe development in India involves the consultants working in tandem with food technologists to harness their knowledge in optimizing the right formulation. This product ideation and strategy formation is then followed by product design and process development. The laboratory conditions differ from industrial production and so is necessary to exercise caution during scale-up by charting out process flow diagrams, suggesting the suitable machinery, formulating layout plants that match with FSSAI (Food Safety and Standards Authority of India) regulations and developing standard operation procedures.
In order to navigate the complexities of food landscape, food consultants zero in on budgeting and cost analysis also. Optimizing day-to-day operations will yield better productivity and enhance efficiency. Evaluation of quality and safety products using chemical and microbiological testing is also crucial in identifying the presence of contaminants and careful monitoring of important parameters (pH, temperature) ensures operational efficiency. There is a necessity in developing food products with longer shelf-lives and texture retention. Failure to do so will adversely impact the retailers and wholesalers. Therefore, careful assessments of ingredients and their interactions, temperature and pH sensitivities, contamination risks, water activity, packaging material and storage conditions are of utmost importance. Familiarizing with the food safety standards, labeling requirements, and complying with permits and licenses in commercial food production will enable to streamline the operations effectively. The consultants also advise on the design of a food pilot plant to replicate the full production before setting up a full-scale commercial facility. This provides an understanding of the existing inaccuracies, and helps in modifying those effectively. The final phase is the launching of product into market. A thorough study of market analysis and identifying consumer choices and current trends will help in achieving sustainable growth. Partnering with the right consultant will be invaluable for a manufacturer looking out for reducing costs, mastering supply chain management and fostering innovation. The acceptance or rejection of food products is strongly dependent upon sensory analysis. The panelists evaluate the properties (taste, flavor, appearance, texture, smell) through their senses and this analysis has been very beneficial in new product development. In addition to this, other factors such as health, emotions, nutritional and social aspects, environment, packaging material etc. sway consumers’ decisions in product preferences
Bakery in India has moved far beyond the neighbourhood bun shop. Over the past three decades the category has evolved from commodity breads and biscuits to a multi-segment industry that spans industrial breads, packaged biscuits, premium patisserie, frozen par-bake/ready-to-bake (RTB) systems, and functional / ethnic bakery innovations. For entrepreneurs, retailers and co-packers this evolution creates technical challenges and commercial opportunities — and a clear place for specialist food consultants to add value.
Following is a brief, technically precise overview of how the Indian bakery landscape has evolved, what is propelling product development, production and process implications you should be aware of, market trends, and how food consultants (e.g., FFCE-type companies) assist companies at each step.
Historical path — from small local to industrial and premium
- Pre-1990s: Small local bakeries, traditional breads (naan, pav), minimal mechanization.
- 1990s–2000s: Inclusion of organized players (modern retail, packaged bread franchises), industrial scale-up (continuous ovens, automatic dough systems).
- 2010s onwards: Premiumization — artisanal bakeries, patisseries, fusion products, and expansion of frozen/RTB supply chains to serve QSRs and hotels.
- Today: A multi-channel industry — retail FMCG breads & biscuits, direct-to-consumer premium patisserie, foodservice frozen par-bakes, and health-/functional bakery.
Market shape & opportunity (high-level)
- The bakery & biscuits business is India’s largest snacking FMCG category. Instead of one number (which, depending on source/time, can differ), see market size in layers:
- Mass-market packaged buns & breads (staple, high volume, low margin).
- Biscuits & crackers (large, branded FMCG category).
- Frozen/RTB & industrial bakery ingredients (increasing rapidly because of QSRs, hotels).
Premium patisseries & artisan (urban focus, higher margin)
Factors contributing to growth: urbanisation, working families, modern retailers, online grocery, QSR growth, improvements to cold chain & freezing, and health/functional positioning (multigrain, low sugar, high protein).
Practical context for the B2B plan: the first consideration — are you selling volume (packaged biscuits / bread) or selling value (premium patisserie, frozen par-bake) or a niche (keto, gluten free, functional). Each option will determine different capex, QC and distribution.
Technical issues — raw materials, formulation and process
A. Raw materials & functionality
- Choice and quality of flour: Improvers and enzymes comprise emulsifiers (e.g., DATEM, SSL) which enhance both freezer stability and crumb softness, oxidizing agents (e.g., ascorbic acid) which enhance dough strength, and amylases, which retard staling in bread.
- Fats & shortenings: Selectively choosing will affect aeration, mouthfeel and shelf life. Interestified fats and palm fractions are employed as substitutes for hydrogenated fats (trans-fat regulation).
- Water quality & salt: Water hardness influences dough rheology; manage mineral load. Salt influences yeast activity, protein strengthening and flavor.
- Functional ingredients: Proteins (WPI, soy), fibres (inulin), seeds, fruit inclusions require formulation adaptation for water, dough stability and shelf life.
B. Process technologies
- Mixing: Spiral and planetary mixers for artisan to small industrial; continuous mixers (dough mixers with dosing) for large-volume lines. Temperature control and dough development are important.
- Fermentation/Proofing: Temperature/time control (retardation for flavour); automatic proofers with humidity control to ensure uniform oven spring.
- Forming & Laminating: Rotary moulder, wire-cut, sheeting and lamination (for croissants/puff) — strict control of fat distribution, gluten network and lamination temperature.
- Baking: Tunnel/retard ovens, rotary rack ovens, and deck ovens for various products. Thermal profiles influence crust colour, Maillard reactions and moisture gradients.
- Cooling & Slicing: Controlled, rapid cooling minimizes condensation and microbial hazard. Slicing lines for packaged bread introduce contamination risks — hygiene & metal detection required.
- Freezing / Par-bake: IQF or spiral freezers for items to frozen supply chain; par-bake tactics (60-80% baking, finish on retail) enable large-scale distribution.
C. Shelf life and packaging
- Bread and other high-moisture baked goods have a longer shelf life because to modified atmosphere packaging (MAP).
- Barrier films and nitrogen flushing preserve crisp items (crackers).
- Antistaling tactics: Enzyme systems, moisture management, packaging permeability engineering.
D. Quality & analytical controls
- Dough rheology (Farinograph, Extensograph) for upstream QC.
- Moisture & aw for shelf life.
- Sensory & texture equipment (texture analyzers for firmness of crumb, shear).
- Microbiological controls: Particularly on cream fillings, custard, cake production and slicing lines. HACCP critical control points: proofing, cream filling, cooling, storage.
- New products & technical advancements
- Frozen retail and par-bake ranges (This includes retailers like grocery stores & QSRs): muffins, croissants, artisan loaves — focuses on freezer-grade formulation & proofing profiles.
- Functional bakery: Protein-bread, fiber/prebiotic breads, low-GI/millet breads — formulation is related to enzyme packages, shelf-life modeling, and compatibility between protein and wheat.
- Ready-to-heat / in-home bake: RTB dough balls, frozen parathes, instant pizza bases — require strong dough formulas to withstand cold chain.
