Healthier reformulation of chocolate bars – innovation for the US market

The challenge

NATRA aimed to reformulate its chocolate bars to meet the evolving demands of the US market: healthier, more nutritious products without compromising the flavour, texture, or sensory experience that define the brand. The challenge was to reduce calorie and sugar content without using artificial sweeteners or ingredients that could alter the product’s profile.

The solution

AZTI applied its expertise in food technology and healthy reformulation to redesign both the recipe and the production process.

The technical team focused on:

• Partial replacement of sugar with natural ingredients with a lower glycaemic index.
• Increasing fibre content to improve nutritional profile and satiety.
• Optimising texture and flavour through pilot trials and sensory panels.
• Assessing consumer acceptance to ensure the new formulation maintained the perceived quality of the original product.

The result was a healthier, stable chocolate bar tailored to the requirements of the international market.

The results

The new bars developed with AZTI:

• Contain 30% less sugar.
• Achieve a 6–10% reduction in total calories.
• Contain no sweeteners or polyols.
• Use no colourings or preservatives.
• Have a high fibre content.
• Maintain their sensory characteristics and achieve a shelf life of over one year.