Food and beverage manufacturers nationwide are facing one of the busiest reformulation periods in recent memory, leading companies to rethink product development and facility operations.
Synthetic colors are at the center of this activity. Several states have passed restrictions on additives like Red Dye 3 and other certified colorants. A product banned from shelves in one state quickly drives reformulation and effectively becomes a nationwide ban. Add to this, the Food and Drug Administration and the Department of Health and Human Services moving to phase out certain petroleum-based dyes, and large retailers announcing their own deadlines for removing dozens of ingredients from private label foods.
This combination of factors is affecting the food and beverage industry significantly because upgrading major food manufacturing lines without disruption is a challenge.
Operational realities of going natural
Synthetic additives play a practical role in extending shelf life, evening out batch variation, enhancing appearance and color and helping products withstand heat, storage and long transport. With many synthetic additives being banned by 2027, food manufacturers will have to tighten process controls and pay closer attention to the small details that keep products consistent.
Natural coloring, for example, is more sensitive to factors like pH, temperature and light exposure. Many natural colorings are also weaker in intensity, which translates to a higher volume of raw products needed to achieve the same appearance. That simple change can alter the way ingredients are stored and handled. A liquid version of a raw input, for examples, may introduce new microbiological risks, whereas a dry raw input might require different cleaning protocols. Even minor recipe adjustments can cause ripple effects that affect blending times, heating and cooling curves, material flow, and line sequencing.
Challenges upstream and downstream
The technical concerns food and beverage manufacturers face come at a time when companies are being asked to make long-term decisions before all bans and regulations are finalized. Manufacturers obviously prefer clarity before investing in expensive line modifications, new equipment and expanded facilities, but the fast pace at which states, governments and retailers are demanding changes makes waiting to reformulate difficult. That means decisions must often be made with incomplete information, running counter to how manufacturers traditionally manage risk.
Supply chain readiness adds another layer of complexity. As demand rises for natural pigments sourced from crops like blueberries, carrots, turmeric and paprika, agricultural producers and processors must scale output in parallel with manufacturers. But boosting crop production, adding processing capacity and expanding logistics networks cannot happen overnight. Bottlenecks at any point in the chain can ripple through production schedules and threaten a manufacturer’s ability to meet retailer commitments.
Designing and constructing for flexibility
In this era, flexibility should be the focus. Plants may need to run legacy formulations alongside natural versions temporarily. Because of this, manufacturers are turning to modular equipment that can be moved, added or repurposed with less disruption. Tanks, mixers and cookers designed for easy reconfiguration allow manufacturing teams to test new formulations while maintaining output of existing products.
Process lines that can switch easily between liquid and dry ingredients offer another advantage. Utility systems involving chilled water, CIP systems, steam and compressed air also need room to grow, since new formulations often demand tighter environmental control. Some manufacturers are even rethinking piping layouts and routing systems so equipment can be rearranged without lengthy shutdowns.
Advancements in processing are helping to ease the transition. Improved high‑pressure processing and refined high‑temperature short‑time methods can reduce color degradation and extend shelf life. Plus, new stabilizing agents based on natural or bioengineered materials are helping manufacturers reduce batch variability. These tools, while not the only solutions, support consistent results as synthetic additives continue to be removed from the food we find in our stores.
Moving forward in a changing food world
With deadlines fast approaching, manufacturers are starting with full‑facility evaluations that look at temperature control, sanitation practices, ingredient handling, zoning, space planning and other key factors. Many are choosing to work with trusted partners who can help them retrofit and build additions using prefabricated or modular construction and engineer-procure-construct (EPC) strategies that help keep quick-turn projects on schedule.
The food and beverage manufacturers who gain the most ground will be those treating reformulation as an ongoing effort rather than a single project with a set deadline. In the foreseeable future, ingredient availability will change, regulations will continue to evolve and consumers will keep expressing their expectations. Plants that can pivot in the face of these disruptors without long delays will be the most successful.
Mark Vermeij, who has three decades of manufacturing experience, is a process technology director at Burns & McDonnell. He can be reached at [email protected].
