Company
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Product
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Design and development
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Manufacture
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Marketing
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Issues and values
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Making use
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Resources
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96% Fat Free Carrot
Cake
About the company
California Cake & Cookie Ltd is a speciality bakery business, based
in Glasgow since 1985. Originally it produced American-style and traditional
British cake slices. Its main customers are the large retail multiples,
independent food shops and catering outlets. Supermarket 'own label'
products are also manufactured by California Cake & Cookie Ltd and distributed
throughout the UK. In June 1996, they launched an innovative range of
low fat cakes of which the 96% Fat Free Carrot Cake is one.
The company is keen to foster innovation and holds weekly meetings
as a way of generating and supporting innovative ideas. The product
development department and the test bakery have introduced many new
products and have earned the reputation for innovation. The company
now employs about 85 people, and the annual turnover target is £2,500,000
and rising.
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About the product
The 96% Fat Free Carrot Cake is similar to the standard of full fat
carrot cake and has been designed to deliver the same flavour and satisfaction.
The cake can be supplied in ambient, chilled or frozen form and has
a shelf life of up to 56 days. It is available in impulse packs to attract
those who want eat cake as a snack. The company prides itself in being
able to supply a range of pack sizes and product varieties to meet specific
customer requirements. Its quality is top-of-the-range and is based
on product freshness linked to shelf life.
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About the design and
development process
The idea for a reduced fat carrot cake was a response to market research.
The company realised that people wanted to eat healthily, but did not
necessarily want to cut cakes out of their diet. So, the challenge was
to design a product that would satisfy people's desire for cake. The
concept of a 96% fat free cake, which delivers the same taste and satisfaction
as a full fat cake, is innovative - it was said that it could not be
done! The success of such a product depended upon careful recipe development
and the reduction of fat content in particular. Fat makes cake moist
and satisfying, so if the fat content is reduced it has to be replaced
with an alternative ingredient that provides the same qualities, and
as close as possible to the same standard.
The company decided to take this idea forward because it wanted to
move into the market for healthy eating and to be a market leader with
a desirable product. In 1996, the company realised that to get a competitive
edge, on the large cake manufacturers who dominate the full fat cake
sector, it would need to come up with something quite different that
would not be easy to copy.
Discussions outside the company, with colleagues who were researching
a high fibre yogurt, resulted in the discovery that one of the materials
being investigated could also be used as a fat replacement. So the company
began to work on finding out how much of the fat content of the cake
recipe could be replaced and whether this would provide a solution.
The ingredient is a naturally occurring starch that has some of the
characteristics of fat. The starch is derived from a specific strain
of barley and is patented.
The nature of the fat replacement material was a key factor in the
development process. This controlled everything since the objective
was to produce a cake which 'tasted like the real thing'. The sugar
content has remained the same as the original recipe.
Aesthetic factors were critical, such as the texture, taste, aroma
and appearance, because cake eating is an indulgence in the mind of
the consumer and these attributes determine how pleasurable this sensory
experience will be. The sensory attributes would need to convince consumers
so that they would buy it.
The development of the original concept to first product launch took
12 months. Each stage in the product development involved tasting, ingredient
analysis and shelf life testing. This was led by the company's technical
and product development teams in conjunction with the scientists who
had developed the fat replacement.
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About the manufacture
During development and trialling, the main issue to be resolved was
the stability of the recipe. The desired fat level in the final product
had to be such that it could be manufactured consistently - ie. time
after time to the same standard.
Raw materials are sourced from standard bakery ingredient suppliers,
except the fat replacement which comes from a special mill in the Borders
of Scotland. This is the only non-standard cake ingredient used, the
others being flour, sugar, water, icing decoration, flavours. Traditional
baking methods are used so that the products retain the 'hand-made -home-made'
look.
The manufacturing processes used do not differ greatly from traditional
cake making. All the raw ingredients have to be checked as part of the
quality assurance procedures. Production on a typical day is 60 racks
with each rack holding 18 pans. Each pan will produce 168 pieces.
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About the marketing
The target consumer group for the product are people who would ordinarily
eat cake, but who also want to maintain a balanced diet without too
high a fat content. The concept and acceptability of a low fat cake
was tested with supermarkets and customers, and market research was
also carried out.
It was important to get the price point right for the product. The
retail selling price must not carry a premium. The recommended retail
price (RRP) for the snack pack is 69p. This meant looking at the marketing
techniques that would be used. The pack design was submitted to consumer
research and the results of this led to the current pack design. The
packaging is used to market the product, as well as to maintain its
safety and quality. The message on the package needed to show that it
is 'light & moist' as well as '96% fat free' because this is what the
consumer will expect from carrot cake. If they are not convinced of
this, they are not likely to try it or make a purchase.
The product is sold through supermarkets, health food shops and catering
establishments where a healthy menu is adopted. California Cake & Cookie
Ltd is an approved supplier to an impressive list of companies in both
the retail and food service business. It is promoted at Food Trade shows,
in food and health magazine articles, through competitions, and supermarket
special offers. It is marketed under a ''hand made-home baked' image
and positioned away from today's 'big plant-made' products produced
by the multinational manufacturers.
The Unique Selling Points (USPs) of the product are that it is:
Low in fat
Low in calories
Free of artificial additives
High in fibre
Per slice the California Cake and Cookie Ltd's cakes have:
a maximum of 90 calories
a maximum fat content of just over 1 gram (this compares with full
fat cakes which typically contain an average of 9 grams of fat)
up to six times the fibre content of standard cakes
and all products are suitable for vegetarians
Sales and profits are tracked weekly and help to determine the success
of the product. The 96% Fat Free Carrot Cake is judged to be a very
successful product, in terms of both the total sales value achieved
and also the number of key supermarkets that have listed the product.
In independent consumer taste tests, the 96% Fat Free Carrot Cake
was preferred to competitive products due to its flavour and moistness.
The company is introducing the first range of convenience dessert
cakes on the market under the name Valentinos. The range is targeted
at both the 30% of UK households that are single and the increasing
number of working families where the parents may eat separately. There
are four products in the range: Tiramisu, Passionata, Cappucino and
Zabaglione. Each pack contains two large individual dessert size slices
and is marketed as an evening shared indulgence with the slogan 'All
you have to decide is which one and with whom!'
More cake recipes are planned to extend the range, as are similar
flour-based products, like biscuits and cereal bars.
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About issues and values
In terms of its impact, the 96% Fat Free Carrot Cake has made the
market sector realise that acceptable fat free products can be made
and are not just seen as a substitute for full fat cakes. It is an
acceptable product to anyone who likes cakes, not just to those who
are looking for a reduced-fat or 'healthy' alternative. This is then
a positive selling point.
Foods are often marketed to appeal to the consumer's concern for
health and nutrition. A food manufacturer or retailer may decide to
alter recipes during development to create foods that will have a
particular appeal, egs. 'reduced fat', 'high fibre', 'low salt'. If
they do so, they are then likely to make a claim about the product
on the packaging. Products manufactured in the UK that make claims
about their nutritional content have to meet the UK Guidelines for
Nutritional Claims.
For fat this means
'Reduced fat' products must have 25% less fat than the standard product
on which it is based.
'Low fat' means that the product contains no more than 5g of fat per
100g, or per serving (to be lowered to less than 3g per 100g later
this year).
'Fat free' means that the product contains no more than 0.15g of fat
per 100g.
It is worth consumers understanding the guidelines, otherwise they
cannot be sure that the product they are choosing is any better than
another. The way in which information is presented on food labels
can be confusing or misleading. Just because a claim about fat is
made, does not necessarily mean that the product is the healthiest
choice, eg. even a low fat product could be high in sugar or calories.
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Making use of the case
study - things to think about and do
Using this case study for the following tasks will help to develop
your understanding about:
- the properties of fat as a material
- industrial practices - recipe engineeering
- new product development - designing for particular
markets
- values issues - food labelling legislation and nutrition
claims
Investigate the different ways in which the fat and/or sugar
content of cakes can be reduced whilst still resulting in an acceptable
end product for the consumer.
Compare the fat content and calorific value of a range of reduced
fat cake products on the market. Carry out a taste test and evaluate
them for consumer acceptability. Firstly, decide on what quality standard
you expect, then ask your tasters to measure the samples against this
standard. Present your findings as a report.
Experiment with food starches and make proposals for other uses for
this ingredient in cakes, biscuits and desserts.
How does the cost of the 96% Fat Free Carrot Cake compare with similar
products on the market? Make sure you carry out a fair test.
Produce a series of diagrams that show a comparison between the large-scale
manufacturing process of cake making and a similar product made by hand
on a small scale. Include safety and quality checks for both.
Explain how the properties of the food materials used for cake making
contribute to the qualities of the end product, egs. moist, sweet, light.
Investigate claims made on a selection of reduced fat and/or sugar
products. Produce a summary of your findings and conclude whether or
not the claims live up to your scrutiny.
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Further useful
resources
'Design & Make it: Food Technology', Stanley Thornes, 1997,
p36-47, p124-125
'D&T Routes: Food', RCA, Hodder & Stoughton, 1997, p61
'Food Technology in Practice', DATA, 1996, p36-37 (Dohler case
study)
'Food Technology to GCSE', Anita Tull, Oxford University Press,
1998, p44-45, p110-111
'Food Technology' Unit, British Nutrition Foundation, 1998,
MAFF and www.nutrition.org.uk
'Interactive CD-ROM' from BNF, Autumn 2000, for modelling cake
ingredients
'GCSE Food Technology', C.Barker, S.Kimmings & C.Phillips,
Causeway Press Ltd. p
'Examining Food Technology', Anne Barnett, Heinemann, 1996,
p56-57, p76
'Food Technology', Collins Real World Technology series, Inglis,
Plews & Chapman, p43-44, p51-54
'Hammond's Cooking Explained', Jill Davies, Longman, 1997,
p79-83, p170-177, p329-337
'Understanding Ingredients', Anne Barnett, Heinemann, 1998,
p22-25
'Get Smart!' or Ridgwell Press 'Modified Starch' teaching
pack containing modified starches for demonstration purposes or experimental
work - see Resources section
'The Science & Technology of Foods', RK Proudlove, Forbes,
1994, p28-45
www.foodstarch.com
www.defra.gov.uk
www.which.net
©foodforum.org.uk 2000. All rights reserved
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