Overcoming the challenges to remove Saturated · PDF fileOvercoming the challenges to remove...

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REFORMULATING THE UK’S ICONIC KITKAT

Overcoming the challenges to remove Saturated Fat


KITKAT – A Global Brand

• York has been the home of KITKAT for over 79 years

• Over a billion KITKAT bars are made in the York

factory each year – making up to 8 million a day

• KITKAT is the most popular confectionery brand in

the world, sold in more countries than any other –

over 17.8 billion fingers eaten a year

• KITKAT has been through a journey to deliver a

product with an improved nutritional value with the

same grate taste and enjoyment for our consumers


What’s in my food?

Where does it comefrom?

How was it made?

Consumer preference

Responsiblesourcing

Nutrition, health and wellness

Environmental sustainability

Permissibility approach+

< 250 calories


October 2013:

Nestlé UK & Ireland announced that it was

reformulating it’s iconic KITKAT bar, which would

result in the removal of 3,800 tonnes of saturated fat

from the diet, improving the nutritional profile of the

product.


Our saturated fat journey

• At Nestlé, our aim is to enhance consumers’ lives with foods and beverages that not

only taste delicious, but offer healthier choices too

• We know that consumers are looking for healthier choices that do not compromise on

taste

• In 2010, the team set themselves a task to review and develop the KITKAT recipe to

improve its nutritional credentials while maintaining the taste that UK consumers love

• A cross functional team of Nestlé scientists, factory technicians, marketing, purchasing

and nutritionists worked with our key suppliers

• After 3 years of plant trials, product approval and engineering changes, we were able

to launch our KITKAT recipe with a av.10% reduction in saturated fat.


KITKAT – The Technical development

• KITKAT is made of layers of wafer filled with a chocolate praline filling and moulded

into the iconic shape of KitKat

• Vegetable fat is present in the KITKAT filling and chocolate shell, with a tiny amount

present in the wafer

• Directive 2000/36/EC of the European Parliament controls the formulation of

Chocolate, in particular the cocoa butter content (rich in saturated fat) and type of

fats in chocolate

• Re-defining the vegetable fat in the filling was the main area of focus

Wafer

Praline


The Recipe Challenge

• As fats become less saturated they become softer and more

liquid (oils)

• The challenge: to identify a fat with the correct melting /

cooling properties to work in our manufacturing plant and to

produce the iconic KITKAT crisp ‘snap’

• Multiple development steps in the laboratory with special fat

melting/cooling equipment testing fats

• Once finalised, the fat then had to be tested in the praline

filling to ensure taste and texture were maintained

• Validation at pilot plant scale to test functionality in

production; reducing the risk of failure before moving to plant

trials

� Any manufacturing issue is a loss to efficiency on the line


Manufacturing challenges

• The filling fat must maintain the same proven functionality across the process – from liquid to

solid at the right time

• It is necessary to avoid any major impact on a 79 years, finely tuned, efficient KITKAT process

• It was all about temperature; tests during winter highlighted problems in the cold weather

• Costly plant stoppages

• Re-develop the new fat, additional time to repeat trials and product tests

• Investment line alterations to keep a robust, efficient process, regardless of the weather!


KITKAT Filling Production; not a simple process


Results – av.10% reduction in saturated fat

For all KITKAT made in York, so what worked……

• Team Work: Multi- discipline team with fat chemistry experts, suppliers, engineers, nutritionists, KitKat technical experts, planners, marketing

• Clear project plan with realistic timing in place

• Budget agreed and communicated internally

• Factory input - support for trials and input from operators to overcome problems

• Robust process and product testing

• Can do attitude – real benefit to the business, consumer and the nutritional profile of KitKat

• Aligned to Nestlé global strategy and Nutritional Policy


KITKAT: An Iconic Brand now with less saturated fat…..

2 finger KITKAT

Before 3.3g Now 2.9g saturated fat per bar

4 finger KITKAT

Before 7.2g Now 6.4g

saturated fat per bar

KITKAT CHUNKY

Before 7.8g Now 6.9g saturated fat per bar


Reformulating the UK’s Iconic KITKAT

A journey that goes beyond the factory gates

Addressing relevant consumer nutrition, health and wellness concerns

Creating tastier, more responsible products

Enhancing our consumer’s enjoyment and experience of the product

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