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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

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