Flavor Development Q&A with an R&D Specialist

How do you make less-than-appetizing ingredients taste like cotton candy? What tools are used to stay on top of flavor trends? Our lead R&D technician, Conner Stinnett, spills supplement development secrets in this casual yet insightful conversation that helps us better understand the necessary balance of art and science when it comes to crafting flavor.

Conner, how does your work influence the supplements manufactured by Factory6?

Creating a sample is my first step, which relies on good communication from the beginning. Our sales team gathers all the information from our prospective clients and I collaborate with our production manager to know machine timelines as well as our purchaser to be aware of any supply chain issues. Then I work with flavor systems, flowability, capsule fill weight, and more to deliver a sample. Asking specific questions at that meeting helps get the product refined. Their feedback leads me to ask more questions, like if it had a bitter note, was it immediate or an aftertaste? Was the sweetness too subtle initially or did it linger too long? Do you want the watermelon flavor to be like a Jolly Rancher or taste like you just bit into a slice in the middle of summer? I can even make it more rindy-flavored. All around, flavor is limitless and particular, so the more detailed we can get, the better. That part of the process is really a lot of fun.

What are the biggest challenges in developing flavors for dietary supplements?

A definite challenge is that everything tastes horrific before you start. For example, Rhodiola rosea root tastes like mahogany, and glutathione tastes like rotten eggs. Neutralizing these beneficial ingredients and making a product people would actually enjoy is a large part of flavor development. Properly educating clients on label regulations when it comes to flavors can be tricky too, but is important. We have to make sure they understand natural flavors, natural flavors WONF, artificial flavors, and why we might need to go a specific route to achieve the flavor they’re after. Some flavors cannot be achieved without the support of secondary flavors, even more so if we are masking certain active ingredients.

Can you describe the process of creating a new flavor? How do you balance taste with nutritional value?

Creating a new flavor involves a step-by-step process. First, I make a base with the desired ingredients and then taste it. Caffeine is bitter, for example, so I already know I need to use specific tricks to mask that or help neutralize it. After that, I choose a flavor that complements the base, considering factors like acidity and sweetness. Working around the desired active ingredients and nutritional content is always prioritized. If a product is super salty, like an electrolyte drink, I have to work with that and can't change it. The goal is to create a flavor that aligns with the overall integrity of the product.

How do you stay ahead of flavor trends in the supplement industry?

Three ways. One way is the monthly reports our flavor houses send us, which tell me their most popular flavors and give market projections for the quarter. Another way is honestly TikTok. It sounds crazy off the bat, but you can spot almost any trend -including supplements- if you’re paying attention. A while back, tart cherry juice and magnesium were huge, so I was encouraging our clients to jump on our product suggestions that included those so they could capitalize on selling to that audience. The third way is just by experimenting with a bunch of things because part of staying out of the curve is making the curve. Fizzy energy tablets to chew up before working out are just fun. No one just thinks of a cola-flavored hangover cure, but consumers crave novelty.

What are some unique considerations when working with different forms, like powders and chewable tablets?

When creating powdered products, it's not simply about specifying amounts in milligrams. The focus is on percentages, considering the final application and the quantity of water or other elements involved. For example, a flavor recommendation might be to start at 0.05 percent in the final application. To understand this, you need to calculate the percentage based on the volume of the end product. The chewable tablet process is a bit more intricate. Although percentages are involved, it's not a straightforward calculation. When chewing a tablet, you're not directly tasting the tablet itself but rather the components dissolved in saliva. This dilution factor often requires a higher percentage to achieve the desired taste due to the dissolving process. Unlike powders dispersing in liquids, tablets pose challenges in palatability and masking flavors, as the ingredients are more directly exposed to the taste buds. 

How do you ensure the stability and consistency of flavors over the product's shelf life?

Largely talking to the manufacturer and their recommendations. Different flavors exhibit varying longevity, with certain ones like chocolate or mixed berry posing minimal concerns about degradation over the shelf life. On the other hand, citrus flavors are prone to losing potency, especially if not stored correctly. For products like citrus-flavored tablets, we typically recommend including an oxygen absorber within the bottle. Specific colored bottles help prevent UV rays from affecting the flavors over time as well. Single-use stick packs are less susceptible to these issues because they aren’t repeatedly opened. The primary considerations in preserving flavor integrity revolve around managing oxygen, moisture, and light, which we take into account when building products for clients. Our work is end-to-end.

Are there any emerging trends in flavors that you're currently excited about?

Lately, we’ve been seeing simpler, lighter flavors. The strong blue raspberry and fruit punch will always be popular because kids and adults love them, but there’s an increase of consumers looking for things like a super light strawberry that’s nice and refreshing. A more relaxed, natural-tasting supplement can be less expensive, so that’s a big advantage. However, it depends on the botanicals and raw ingredients they want to use.

Where do you see the future of flavor science heading, especially in the dietary supplement industry?

I've noticed that ingredients seem to be improving over time. The process of isolating components has advanced considerably, especially compared to a decade ago when you'd simply get a bulk powder. Nowadays, extraction methods have become more sophisticated, allowing for higher percentages of specific compounds. Like in turmeric, there’s this curcuminoid, that's actually white in color and it presents in such small amounts, but they've been able to isolate it, synthesize it, and then use it as a supplement. It has some great effects, but no one would have ever known about it because they couldn't detect it at such small levels in turmeric before. Also, masking and flavor modification technologies have seen remarkable progress. I recently collaborated with a company specializing in masking agents and modifiers, and they've developed agents tailored to hit BCAAs, BHB salts, and Dynamine, a branded nootropic, among many more. Advancements are only going to get better, and although costs initially tend to be high, they usually even out over a few years. 

Ready For A Brand Revolution?

If you want to make a splash and redefine the game, Conner and the rest of the Factory6 team are here to be your guide in creating products that not only meet but exceed consumer expectations. Start a flavor revolution for your brand and become a trailblazer in the supplement industry. The future of flavor awaits – are you ready to seize it?