Sensory reverse engineering: A framework for sustainable product development used on vegan chocolate mousse

Abstract

This study presents a sensory reverse engineering framework designed to optimize food formulations by integrating consumer sensory preferences early in the development process. The framework was applied to the development of a vegan chocolate mousse, a product that meets growing consumer demand for sustainable, plant-based alternatives. The challenge of replacing eggs, which provide critical texture and aeration in traditional mousses, was met with aquafaba (chickpea cooking water) and apple pomace, a by-product of apple processing. While these ingredients offer sustainability benefits, they present sensory challenges such as bitterness and textural variation that require careful formulation.

The framework used Design of Experiments and external preference mapping to systematically optimize the ingredient proportions. Key factors, including margarine, hazelnut milk, and sugar were evaluated for their impact on sensory attributes such as texture, flavor, and appearance. Sensory profiling was conducted with trained panelists, while consumer hedonic testing with 94 participants provided insight into overall product acceptability.

Multi-objective optimization identified the ideal formulation: the optimal vegan mousse formulation achieved a desirable balance of sweetness, texture, and flavor while closely mimicking the sensory qualities of traditional mousse. The final product demonstrated that plant-based ingredients can replicate the sensory experience of egg-based mousses and promote the use of by-products.

In conclusion, the sensory reverse engineering framework provides a robust, consumer-driven approach to food product development. By incorporating consumer feedback into the early stages of formulation, the framework reduces the risks associated with traditional product development, resulting in products that are better aligned with market expectations.