Popcorn Flavours: Formulation and Characterization

• All dry spices including sea salt, dill, ground chili, and the natural spice blend were dry roasted to enhance aroma and reduce moisture.
• They were then blended uniformly to create a homogenous spice blend.
• Powdered ingredients such as dextrose, powdered sugar, tomato powder, binder, dry whey, fructose, natural preservative, yeast extract, paprika extract, and cayenne pepper extract were measured and prepared separately.

• All powdered ingredients, including sugars, tomato powder, starch, dry whey, and the spice blend, were combined in a clean mixing vessel and mixed thoroughly to ensure even distribution.
• Encapsulated lime flavor and encapsulated garlic oil were added and mixed gently to prevent loss of volatile components.
• The anticaking agent was added to prevent clumping and maintain powder flow during storage and application.
• The formulation was separated into three variants:

Variant 1 – Shrimp flavour

Variant 2 – Tomato with greens

Variant 3 – Truffle flavour

Starch (10% of the blend) was included as an adhesion agent, and it was thoroughly dispersed within the seasoning mix to improve the seasoning’s ability to adhere to popcorn surfaces.

• Blending: The prepared dry powders were introduced into a blender to ensure homogeneous mixing of all ingredients.
• Sieving: The blended mixture was sieved to obtain a uniform particle size and consistent texture across all flavor variants.

• Storage stability tests were conducted to assess flavor retention, color stability, and anti-caking performance over time.
• Ingredient ratios and processing parameters were optimized based on test results, and the process was prepared for scale-up while maintaining the roasting, blending, and mixing conditions.