Many bakers are actively seeking replacements for current sources of oils and shortenings because of widespread media coverage about health-related issues attributed to certain fats and mandatory legislation stipulating a ban on trans fat. But, switching from one fat type to another isn't necessarily as simple as making a one-for-one replacement and should be considered on a product-by-product basis.

“Bakers are aware of the need for next generation oils; however, they are challenged in how to incorporate these new formulations without altering the quality or taste of their product,” says Ryan Overton, market research and sales analysis associate, Asoyia Inc., Iowa City.

The research and testing required in selecting a new oil or shortening is costly and time consuming, particularly for smaller bakers who lack the necessary funds to compete with larger operations. This provides an opportunity for oil suppliers to open a dialog with bakers and serve as technical advisors, Overton adds. In doing so, these new generation products can be incorporated into existing product lines without adversely affecting product quality.

Factors driving change

An increase in awareness of the heart disease-related risks associated with trans fat led to large-scale product development efforts of alternative oils. Trans fat, although naturally occurring in butter and other animal-based fats, is created when fat is hydrogenated, which increases its melting point and improves its stability and shelf life.

In 2006, the FDA mandated the labeling of trans fat, stipulating that any product with a serving size containing 0.5 g or more of trans fat must list the amount under saturated fats on its nutritional facts panel. Trans fat amounts of less than 0.5 g can be labeled as 0 g trans fatty acids in the nutrition facts panel, but the trans fat-containing ingredient, such as shortening or partially hydrogenated vegetable oil, must be listed in the ingredient statement.

Since the FDA's ruling, cities and now states, such as California, have banned the use of trans fat. And, the American Medical Association has suggested a nationwide ban of trans fat might be appropriate, notes Gerald McNeill, Ph.D., director of research and development, Loders Croklaan North America, Channahon, Ill.

Labeling laws and mandates have, in many cases, forced bakers to search for oil alternatives. But, in some circumstances, bakers are motivated by consumer demand for more healthful options.

New fat innovations

“For the baking industry, because they need more solids in their fat systems, most who have made the change from partially hydrogenated have switched to palm or palm blends. Now you see, as a phase two, people trying to move away from all the saturated fat that is in palm. You also are seeing some people changing back to butter-type products,” says Beth Fulmer-Boyer, vice president of sales, Asoyia.

Still, some bakers who have not directly addressed the trans fat issue may just be looking at the first round of lowering trans fat in their formulations, notes Lynne Morehart, technical services manager, Cargill Oils, Minneapolis.

One replacement solution for trans fat shortenings is a reduced-fat, all-purpose bakery shortening made from a blend of palm oil and canola oil. “It contains about 30 percent less saturated fat than typical zero-trans shortenings, but retains 100 percent functionality,” McNeill says. “It is designed to be a drop-in solution for saturated fat reduction in any application requiring an all-purpose shortening, such as cookies and cakes. It has a lighter texture than regular all-purpose palm oil shortening. Therefore, creaming time is shorter, and up to 15 percent less fat can be used without altering finished product texture. This has the benefit of further reducing the saturated fat content and may provide a cost savings.”

Palm oil also is a versatile alternative to partially hydrogenated oils, and may be a drop-in solution, even in difficult applications, such as laminated doughs, McNeill adds. Because palm oil contains no linolenic oil and a low level of unsaturated fatty acids, its stability is comparable with that of partially hydrogenated oils. Still, if saturated fats are a concern, blends of palm oil fractions and canola oil are available, as previously mentioned.

The introduction of next generation oils also includes low linolenic soy, ultra low linolenic soy and high oleic canola-omega-9 oils, Overton notes. Introduction of new processing enhancements without partial hydrogenation has opened the door for zero-trans shortenings for the baking industry, he adds.

The future of fats and oils

Ever evolving science on fat consumption and human disease risk factors will continue to influence new product development. Additional studies are likely to influence future generations of oil, just as research has increased development work of oils rich in omega-3s.