Malt Extract in Cereal Bars and Breakfast Foods: Formulation Considerations

Introduction

The current trend of convenience and versatility of foods is seen in cereal bars and breakfast foods. There are granola bars, breakfast bars, muesli, cereal clusters and breakfast products in which manufacturers keep trying out ingredients that offer good quality, taste and texture of the food.

Malt extract in cereal bars and breakfast and breakfast foods may help in achieving these goals due to its characteristic malty flavor, color and soluble sugars. In some cases, it could help bind the ingredients of the cereal bar or breakfast food product.

Understanding the functional characteristics of malt extract is very important for food manufacturers who are making cereal-based foods. They need to use appropriate type, concentration and processing methods to obtain the required characteristics.

What Is Malt Extract?

Malt extract is an ingredient which usually comes from malted grains such as barley using the process of extraction and concentration. The composition of the malt extract consists of various proportions of carbohydrates and other natural substances found in malt, based on the raw materials used and manufacturing process.

There are two types of malt extract that exist, one in liquid form and another in powder form. Both could be considered for use in food formulations made with cereals, based on the processing equipment available for the manufacture and moisture content needed.

Liquid malt extract is useful in cases where there is a need for a concentrated liquid ingredient, while dried malt extract is applicable when there is a need for a powdered ingredient.

Applications of Malt Extract in Cereal Bars and Breakfast Foods

1. Cereal Bars and Granola Bars

Cereal bars usually have ingredients such as oats, puffed cereals, seeds, nuts, and dried fruits. This combination needs to happen in such a way that will result in a cohesive product while preserving the required texture.

The malt extract can be added to specific recipes for the cereal bars for both flavour and contribution of soluble solids. The inclusion of the extract, depending on its concentration and other ingredients, will also help in forming the cohesion of the cereal bar.

One needs to look at the moisture content, viscosity, and how the extract interacts with other binders like syrups.

2. Breakfast Bars

Breakfast bars can come in various forms like soft baked, chewy and crunchy.

The malt extract could offer the characteristic flavor profile and also affect the carbohydrate content of the product.

The inclusion of the ingredient in soft breakfast bars needs attention as it affects softness and stickiness of the product. The inclusion of this in crunchy breakfast bars needs to be tested carefully due to the potential change in texture of the bars.

Product testing becomes imperative in establishing the right inclusion levels.

3. Muesli and Granola Products

Muesli and granola are made up of cereal flakes, nuts, seeds and dried fruits. The choice of whether to add the malt extract will be depending on whether the manufacturer wants to include it in the flavoring system or in a coating blend for the clusters of cereal.

The choice of coating material may affect the adherence of the cereal clusters in granola manufacturing. This is because the malt extract may help in this process along with other suitable binders and processing methods.

It also has a distinct flavor which can be added to the flavors of roasted cereal, nuts and seeds.

4. Ready-to-Eat Breakfast Cereals

Ready-to-eat breakfast cereals include flakes, puffed grains, extruded cereals and many others.

Malt extract may be used as an ingredient in the cereal or added in the coating of the product depending on the type of processing technique used. Malt extract can add a certain taste and colour from the malt, while its carbohydrates may have an effect on its processing.

The performance of the ingredient in mixing, extrusion, drying, baking or coating needs to be evaluated by the manufacturers.

Key Formulation Considerations When Using Malt Extract

Successful product development requires more than selecting an ingredient. Manufacturers must understand how malt extract interacts with the complete formulation and the production process.

1. Flavour Profile

The malty flavor of the malt extract may be used as an enhancement of the flavors of oats, wheat, rice, nuts, and seeds. This depends on the type of extract used, its amount in the product, and other ingredients added to it.

The food manufacturer should make sensory tests to determine which flavor profile will fit the product well. Too much or too little usage of this ingredient will not provide the desired flavor.

2. Binding and Texture

Sufficient cohesion is required by cereal bars to hold their shape throughout cutting, packaging, transport, and consumption.

While malt extract can serve as a source of cohesion in certain recipes, its efficiency can depend on the recipe itself, the moisture content, and the temperature.

Such pilot-scale experiments can allow food companies to find the right balance between cohesion, chewiness, firmness, and stickiness.

3. Moisture Management

The moisture content is significant for the textural characteristics and storage stability of cereal bars and breakfast foods.

Liquid malt extract adds moisture to a formula. The company may have to compensate for this by changing other components or baking processes in order to get the desired effect.

It is also necessary to consider the water activity in such cases, as it determines the microbiological stability and shelf life of the product. These two values are interconnected but not equal.

4. Colour Development

The malt extract is capable of adding coloration to cereals. In baking and heating processes, it can have an effect on the appearance of the product due to its reactions with other ingredients.

The manufacturers should consider color consistency from batch to batch.

5. Sweetness and Carbohydrate Composition

Malt extract is rich in carbohydrates, whose levels of sweetness are dependent on the composition of the product. Malt extract can add to the carbohydrate levels in the product.

The food manufacturer needs to examine the ingredient specification and nutritional contributions when formulating a product. Malt extract cannot be categorized as sugar free or low sugar product.

6. Processing Compatibility

The appropriateness of malt extract depends on how it is produced. Various processes such as mixing, extrusion, baking, drying, and coating may affect the suitability of an ingredient.

Prior to large-scale manufacturing, it is important for food scientists to conduct tests involving mixing behavior, temperatures, consistency, and quality of the final product.

Liquid Malt Extract vs Dried Malt Extract for Cereal Applications

Both liquid and dried malt extract can be considered for cereal bars and breakfast food formulations.

Formulation factor	Liquid malt extract	Dried malt extract
Ingredient format	Concentrated liquid	Powder
Incorporation	Suitable for liquid mixing or syrup systems	Suitable for dry blending or compatible mixing systems
Moisture impact	Adds moisture to the formulation	Generally contributes less moisture, depending on specification
Handling considerations	Requires suitable liquid storage and handling	Requires protection against moisture uptake and caking
Best selection approach	Evaluate viscosity, solids content and mixing requirements	Evaluate solubility, particle properties and dispersion

The right option depends on the formulation, equipment, storage conditions and product specifications. Manufacturers should review technical data and carry out application trials before finalising ingredient selection.

Quality and Shelf-Life Considerations

Quality consistency is important when manufacturing cereal bars and breakfast products.

The following considerations should be made by manufacturers when assessing malt extract:

• Specification of ingredient: Consider the solids, moisture content, color and other pertinent considerations.

• Consistency within batches: Consider variability that may affect flavor, texture or performance during processing.

• Microbial quality: Consider appropriate safety standards for ingredients and finished products.

• Compatibility of packaging: Consider the packaging and handling requirements of the ingredient.

• Stability of finished product: Consider texture changes, moisture transfer, oxidation and other pertinent shelf-life considerations.

Shelf-life tests need to be done using the formulation and packaging of the finished product. This cannot automatically be extended from one cereal bar/breakfast cereal formulation to another.

Choosing a Malt Extract Supplier for Food Manufacturing

Choosing a right malt extract supplier is a significant part of product development process. In addition to cost and availability factors, a manufacturer should make sure that the ingredient fits his or her technological requirements.

The key criteria for evaluating suppliers are:

1. Product specifications: Make sure that the ingredient fits the formulation.

2. Supply reliability: Check the possibility to place repeat orders.

3. Technical information: Ask for the relevant product specifications, certificates and food safety information.

4. Compatibility: Test the ingredient in laboratory/pilot scale.

5. Logistics: Check the storage conditions, shipping etc.

6. Regulatory and allergen information: Analyze the appropriate ingredient declarations.

For export sales, it is necessary to check the requirements to the documentation and labeling in the destination country.

Conclusion

Use of malt extract in cereal bars and breakfast and breakfast products gives food processors a choice of ingredients with which to formulate unique flavour, colour and product characteristics. Contribution that it can bring to the binding and texture aspect of the formulation is determined by the total formulation and the manufacturing process.

In cereal based products like granola bars, breakfast bars, muesli and ready to eat cereals, careful thought must be given to the moisture content, processing capability and performance of the malt extract selected.

By choosing the correct ingredients through formulation and quality evaluation, cereal food manufacturers can make better decisions regarding the development of their cereal products.

If you are considering using malt extract in your next cereal bar or breakfast product formulation, contact an appropriate malt extract supplier.

Frequently Asked Questions

1. What is malt extract useful in the making of cereal bars?

Malt extract is helpful in providing malty flavor, coloring and soluable carbohydrates in cereal bars. In certain formulas, it could help with cohesion when added along with other binding ingredients.

2. How does malt extract fit in with granola and muesli?

Yes. The use of malt extract could be thought about when considering the production of granola, cereal clusters and certain kinds of muesli.

3. Which form is better for breakfast foods, liquid malt extract or dried malt extract?

Neither form is better than the other. Liquid malt extract could be more suitable for the liquid mixer, while dried malt extract could be easier to work with for some dry mixtures.

4. Does malt extract influence the texture of cereal bars?

Yes, it could affect the texture by virtue of the soluble solids, moisture content and reactions with other ingredients in the mixture.

5. Can malt extract be used in place of sugar in cereal bars?

While malt extract could provide sweetness and carbohydrates, it is not always a direct sugar substitute. Tests need to be done to assess the suitability in terms of sweetness, binding properties, moisture and nutritional content.

6. Is malt extract a good choice for gluten-free breakfast items?

Regular barley malt extract is not suitable for gluten-free items unless it complies with the relevant gluten-free criteria. Suppliers and manufacturers should ensure that the ingredients and the final product meet these criteria.

7. What are the factors in choosing malt extract for cereal products?

The supplier needs to consider the specifications of the ingredient, taste, moisture, processability and the availability. Trial testing may be necessary for the particular application.