Breaking boundaries in bread innovation in the USA

Breaking Boundaries in Bread Innovation in the USA

Breaking Boundaries in Bread Innovation in the USA

Manildra Group USA is breaking new ground in the low-carbohydrate market with FiberGem®, a premium resistant wheat starch for baked goods.

Packing a more nutritious punch for health- conscious consumers, Manildra Group USA has perfected the low-carb blend using FiberGem® as the hero ingredient containing more than 90 per cent dietary fibre.

The revolutionary product has opened the door to exciting possibilities in low-carb, high-protein product development.

This includes innovative prototypes being trialled in Manildra Group USA’s Dr Sukh Bassi Innovation Centre in Leawood, Kansas, United States.

“The challenge for low-carb baking, is that flour, which is largely comprised of carbohydrates, is a key ingredient for baked goods – so the challenge is to rebuild the necessary structure into a low-carb, functional flour ingredient blend,” Manildra Group USA Vice President of Research and Development, Brook Carson told The Cultivator.

From an initial launch in early March 2020 supplying low-carb tortillas, and extending to breads and bagel markets in early 2021, Manildra Group has grown to become a pioneering industry leader, supplying the low-carb market with the optimal recipe formulations including our FiberGem® and GemPro® products.

Ms Carson said that Manildra Group USA’s expert team creates highly-customised product formulas and that the perfect low-carb flour blend replacement begins with a combination of Manildra Group’s FiberGem® (resistant wheat starch) and GemPro® (wheat protein).

Manildra Group’s FiberGem® resistant wheat starch is more compatible with flour already used in bakery formulations to achieve the desired texture, neutral flavour, and bright colour – it mimics flour, without the carbs,” Ms Carson said.

As a wheat starch, FiberGem® does not disrupt the absorption or dough properties of the product. This enables it to fit seamlessly in any formula, used as a direct flour substitute up to a certain percentage in various applications, whilst providing an outstanding fibre source with fewer net carbohydrates.

“The bright white colour and low absorption rate makes FiberGem® ideal for achieving the right functionality from the mixing bowl through to the oven. We also adjust the finished product texture, from more strength for a chewy texture, to softer and more extensible doughs for a finer bite with our GemPro® protein,” Ms Carson said.

“Once we determine the ratio of FiberGem® to GemPro®, you can simply drop it into your conventional formula. The very best part of this solution is that you can add this low-carb flour blend with minimal changes to formulations or baking processes.”

Ms Carson said that it was crucial the recipe was developed with the finished product in mind, and that the recipe was low-carb and high-protein, without sacrificing taste or texture.

The USA is a high-performing, fast paced market with new product lines expanding rapidly including in breads and buns and exciting innovations in low-carb English muffins, a yeast-leavened bread for which the fermentation process creates crooks and crannies to cradle delicious toppings.

“Nutritious without compromising on taste, texture or the flavour of an English muffin,
as well as delivering a shorter mix time with a more fluid dough that easily fills a griddle cup and creates an open cell structure – it’s a science to perfect, but the result has been so worth it.”

“There’s a huge demand for high-protein and low-carb bakery items and by substituting ordinary flour with our recipe of FiberGem® resistant wheat starch and GemPro® HPG and GemPro® Prime-E proteins, we are delivering delicious and better-for-you foods,” Ms Carson told The Cultivator.

Markets are also emerging as consumer demand rises for a premium yet highly-nutritious burger bun, but according to Ms Carson, this can be challenging to produce, particularly with the correct pan flow, strength, and finished appearance.

Additionally, Ms Carson said low-carb buns relied on an ideal blend of fibre and protein to create a low-carb flour with the perfect functionality to match traditional wheat flour.

It also required visco-elastic properties improvements with a combination of FiberGem® for body and absorption to mimic the starch component of flour, and GemPro® wheat proteins for functional benefits from elasticity and strength to extensible and film-forming features.

“The key components in developing a low-carb flour-based product requires replacing carbs with fibre, protein or fat.”

“GemPro® proteins provide the structural component in low-carb applications – forming the gluten matrix ordinarily presented in flour, to balance elastic and extensible properties for optimised handling and specific end-product characteristics.

“FiberGem® delivered the critical fibre component for low net-carb results in bakery items with a bright white colour and minimal impact on flavour or texture.

“As people develop a greater understanding of digestive and gut health, sweet and savoury baked goods that are rich in fibre and low in carbs will become the go-to for healthier indulgences,” Ms Carson said.

For all product enquiries contact Manildra Group USA President Neal Bassi at