Tagline
Maintaining Product Consistency Through Sensory Science
Client
A leading ice cream brand seeking to optimise its ingredient sourcing by qualifying new chocolate coating suppliers without altering the sensory experience that consumers associated with the brand.
Background / Challenge
Ingredient supply chains are constantly evolving, driven by cost volatility, supplier availability, and changing sourcing strategies. However, for established food brands, even a small change in ingredients can alter the consumer experience.
For premium chocolate-coated ice cream bars, the sensory signature extends far beyond flavour. The characteristic snap of the chocolate shell, the cocoa profile, the melt behaviour, and the lingering mouthfeel together define the brand experience.
When the client’s primary chocolate coating supplier became unavailable, the objective was clear:
- Qualify alternative ingredient suppliers
- Maintain the product’s signature sensory identity
- Ensure consumers experienced no perceptible difference in taste, texture, aroma, or overall indulgence
- Protect brand equity while enabling a seamless supply chain transition
The challenge was to make a significant sourcing change completely invisible to the consumer.
Approach
Thinking Forks applied a science-based sensory evaluation framework to objectively measure and compare the sensory characteristics of the existing product with alternative formulations.
Developing a Sensory Benchmark
The original product was first mapped using a descriptive sensory analysis (Spectrum Method) to establish its sensory fingerprint.
The evaluation measured 11 sensory attributes on a structured intensity scale, including:
- Chocolate snap (first bite)
- Melt rate
- Mouthfeel
- Cocoa intensity
- Vanilla profile
- Creaminess
- Residual coating
- Overall flavour balance
This benchmark became the reference standard for all subsequent formulation trials.
Evaluating Alternative Formulations
Multiple chocolate coating systems from prospective suppliers were evaluated against the established sensory benchmark.
Each trial was assessed to determine its ability to replicate the original consumer experience while meeting technical and commercial requirements.
One promising formulation initially appeared visually identical to the benchmark. However, detailed sensory profiling identified critical differences that would likely influence consumer perception.
The evaluation revealed:
- Loss of the characteristic chocolate snap
- Reduced cocoa depth and flavour complexity
- Overall sensory profile inconsistent with the brand’s established identity
Based on these findings, the formulation was rejected despite its close visual resemblance.
Optimising for Sensory Equivalence
Working collaboratively with the client and ingredient partners, Thinking Forks refined subsequent formulations through iterative evaluation.
The final formulation successfully restored the defining sensory characteristics, including:
- Signature chocolate snap
- Cocoa intensity and flavour depth
- Balanced melt profile
- Overall consumer experience aligned with the original product
The optimisation process also ensured that subtle variations, such as increased creaminess or coating behaviour, remained within acceptable sensory limits while preserving the brand’s distinctive identity.
Results Delivered
- Qualified an alternative chocolate coating supplier without compromising brand identity
- Established a detailed sensory benchmark using the Spectrum Method
- Evaluated multiple formulation trials through objective descriptive sensory analysis
- Identified critical sensory differences that were not detectable through visual assessment alone
- Successfully restored the brand’s signature sensory profile through formulation optimisation
- Enabled a seamless ingredient transition while protecting consumer trust and product consistency
By combining sensory science with formulation expertise, Thinking Forks helped the client navigate a complex supplier transition without compromising the experience consumers had come to expect.
Closing Statement
At Thinking Forks, we help brands optimise formulations, qualify new ingredients, and improve supply chain resilience without compromising the sensory experiences that define consumer loyalty. Through science-led sensory evaluation and product optimisation, we ensure every product continues to deliver on its brand promise.
