Almond Oat – RTE Bowl: Formulation, Shelf-Life Assessment, and Evaluation of Swelling Capacity

client

Almonds Oats

Our Role

We redefined fast-casual loyalty

Today’s Task

What We did Today?

Event: Formulation of Almond Oat – RTE Bowl: Physicochemical and Sensory Characterization

Today’s task focuses on the development and optimization of a novel Almond–Oat Ready-to-Eat (RTE) Bowl tailored to meet the preferences of health-conscious consumers in the USA. We aimed to formulate this product using almond milk as the primary base which imparts characteristic nutty flavour and smooth texture. Oats were also considered as it contributes to nutritional density, viscosity, and mouthfeel. To further enhance the functional profile, selected nuts and seeds were incorporated, enriching the product with plant-based protein, dietary fibre, and essential micronutrients. Additionally, natural non-caloric sweeteners were employed to achieve sweetness equilibrium, which aims to deliver improved nutritional balance, sensory appeal, and consumer acceptability.

How I Felt Before Starting – Developing a naturally flavoured RTE functional food

Formulating the almond–oat RTE bowl balancing both nutritional integrity and sensory quality presents several technical challenges. Key difficulty lies in achieving the optimal consistency and mouthfeel with almond milk without being too viscous or too fluid. Additionally, controlled hydration of seeds and effective shelf-life management are crucial to attaining the desired texture, taste, and visual appeal of the final formulation. Each of these parameters were systematically optimized through an in-depth understanding of advanced food processing technologies, optimizing ingredient ratios, and flavour retention mechanisms.
almonds-oats-bowl (2)
almonds-oats-bowl (1)
almonds-oats-bowl (2)
almonds-oats-bowl (2)

🧪 What We Did Today?

Product Development Plan –

 

Preparation and Quality Assessment of Almond Oat-RTE Bowl

    • Optimization of functional ingredients to attain balanced texture and mouthfeel.
    • Pasteurization to extend the product shelf life
    • Assessing the physicochemical and sensory attributes of the final product

Key Steps Followed Today:

  • Raw almonds were accurately weighed, blanched, and peeled to remove the seed coat.
  • The peeled almonds were tray-dried at 60°C for 20 minutes to eliminate surface moisture.
  • The dried almonds were blended into a smooth paste by adding measured quantity of water as two variants. It was then filtered through a muslin cloth to achieve a refined almond milk consistency.

Variant 1 – Almond and water ratio was 1:3

Variant 2 – Almond and water ratio was 1:3.5

  • The obtained almond milk was pasteurized at 85°C for 30 seconds with continuous stirring to ensure microbial safety and stability.
  • Rolled oats were soaked in hot water (90°C) at a 1:2 ratio (w/v) for 60 minutes, followed by draining the excess water.
  • Chia seeds and flaxseed meal were hydrated in 10 mL of the prepared almond milk for 10 minutes to improve texture and water-holding capacity.
  • Separately, additional seed powder, flavour enhancer and non-calorie sweetener were weighed and kept ready for incorporation.
  • The soaked oats, hydrated chia and flaxseed mixture, almond milk, natural flavoring, sea salt, and non-caloric sweetener were combined and mixed gently until a uniform, spoonable consistency was achieved.
  • The final almond oat mixture underwent high-temperature pasteurization to enhance microbial stability and extend shelf life.
  • The pasteurized product was then filled into pre-sterilized packaging containers and hermetically sealed under hygienic conditions to preserve freshness, texture, and nutritional quality.

📚 What I Learned?

Observations & Learnings

  • Consistency and Hydration: The consistency of variant 1 was observed to be too thick, indicating inadequate hydration of dry ingredients. This likely resulted from insufficient water absorption by oats and seed components, leading to a dense and less uniform mixture.
  • Sensory Attributes: Variant 2 exhibited a palatable consistency with a balanced texture and appealing appearance. The improved hydration resulted in a smoother blend and desirable mouthfeel, contributing to its overall consumer acceptability.

Outcome

Nutritional Information per 100g

Nutrient

Amount (g)

Carbohydrate

16

Protein

2

Fat

4

Fibre

1

 

Shelf life: Unopened packs can be stored under refrigeration (4 ± 2°C) for up to 2–3 months without significant quality deterioration.

Opened packs should be consumed within 2–3 days to ensure optimal freshness, flavour, and microbial safety.

Organoleptic evaluation

Quality

Variant 1

Variant 2

Appearance

7.2

7.4

Colour

7.3

7.5

Flavour

7.5

7.4

Taste

7.3

7.3

Texture

7.2

7.4

Mouthfeel

7.2

7.3

Overall Acceptability

7.3

7.5

Organoleptic evaluation of DEsi Noodle Flavors conducted at FRL sensory Lab

Total Plate Count (TPC)

  • Variant 1 exhibited a lower microbial load, which can be attributed to its reduced moisture content, creating an environment less favorable for microbial growth.
  • In contrast, Variant 2 showed a slightly higher microbial count compared to Variant 1, likely due to its higher moisture availability, which supports microbial proliferation.

Swelling properties

  • The swelling capacity of variant 2 was notably higher, resulting from its greater moisture content. This enhanced water absorption contributed to a softer texture and improved mastication quality.
  • Conversely, variant 1 demonstrated lower swelling properties due to insufficient hydration, leading to a denser and firmer texture in the final product.

What Went Well

  • Ingredient selection and mixing contributed to a highly acceptable flavour and texture, enhancing overall product appeal.
  • The almond milk, initially thin, thickened after pasteurization, aligning well with the desired product consistency.

⚠️ What Could Be Improved

  • Colour enhancement can be achieved by incorporating fruit extracts or natural colorants to improve visual appeal.
  • Optimizing hydration levels can further refine texture and consistency in the final product.
  • Sweetness optimization is recommended to balance the flavour profile and complement the functional ingredients

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