STORIES IN THE MAKING
Avoiding Formulation Pitfalls in Shelf-Stable Beverages: Insights for UHT Producers
As demand for shelf-stable, high-protein beverages continues to grow, pressure on dairy, plant-based and nutritional beverage producers has never been greater. Consumers expect clean labels, functional benefits and exceptional taste and they are not willing to compromise on quality.
When developing products for Ultra-High Temperature (UHT) processing, formulation decisions can determine success or failure. The ingredient list shapes more than the nutrition label. It also affects flavor, texture, microbial stability and heat tolerance.
At SPX FLOW, we have supported hundreds of pilot trials at our global UHT innovation centers. One finding is clear: many challenges in shelf-stable beverage development are preventable with earlier testing and stronger formulation planning.
Here are five common pitfalls and how R&D teams can avoid them.
1. Underestimating Heat Sensitivity of Functional Ingredients
Ingredients labeled “heat-stable” in lab tests may behave differently under commercial UHT conditions. Vitamins, probiotics and polyphenols can degrade quickly when exposed to full thermal profiles.
Tip: Confirm ingredient performance through pilot trials that match holding times, temperatures and heat-up and cool-down rates used in production. This gives accurate retention values and helps adjust concentrations or process parameters before scaling up.
2. Incomplete Understanding of Protein Behavior
High-protein beverages, especially those with plant-based proteins, are highly sensitive to heat. Even when a formula looks sound, gelling, sedimentation or grainy textures can appear during processing.
Tip: Test the formulation using the same UHT configuration planned for full-scale production. Infusion, tubular, injection and plate systems apply heat and shear differently, which affects protein solubility, stability and mouthfeel in the finished product.
3. Overlooking Ingredient Interactions
Problems often result from how ingredients interact, not just how they perform alone. Emulsifiers, stabilizers and fortifying agents can react unpredictably under high shear or heat, leading to phase separation, viscosity drift or poor textures after packaging.
Tip: Evaluate the full formulation under realistic mixing and UHT conditions instead of testing ingredients individually. Identifying interaction-related issues early can prevent costly reformulations and production delays.
4. Assuming Lab Simulations Will Translate to Reality
Laboratory testing is helpful but often misses the complex conditions of commercial UHT processing. This is especially true for new ingredients or emerging products such as plant-based milks, shelf-stable lattes or functional wellness shots.
Tip: Use pilot-scale trials to mirror production conditions closely. At SPX FLOW, brands have saved months of development time by detecting texture, flavor or stability problems during pilot testing that lab simulations overlooked.
5. Ignoring Sensory Shifts After Processing
Technical stability alone does not ensure consumer acceptance. A product can survive UHT treatment yet fail on taste, aroma or texture.
Tip: Include sensory analysis in pilot trials. Compare how different UHT methods such as infusion, injection, tubular and plate systems influence flavor and mouthfeel throughout the product’s shelf life. This confirms the product will deliver on both performance and sensory experience.
Why This Matters More Than Ever
The market for shelf-stable beverages from high-protein shakes to plant-based milks is expanding quickly. With more brands competing, consumer expectations are rising. There is less tolerance for chalky textures, off-flavors or sedimentation, and clean label demands are driving the need for smarter formulation strategies.
Speed to market matters, but effective formulation and real-world testing separate leading brands from the rest. SPX FLOW’s UHT innovation centers give producers an advantage through the expertise of our process technologists, laboratory facilities and aseptic filling capability.
Partner With SPX FLOW to Accelerate UHT Innovation
Shelf-stable beverages do not have to involve trade-offs. With the right formulation planning and access to pilot-scale UHT testing, producers can deliver clean label, high-protein products that meet expectations for quality, taste and stability.
At SPX FLOW, we work with producers worldwide to:
- Simulate full-scale UHT processing at our innovation centers in North America, Europe, Asia and the Middle East
- Improve protein solubility and heat stability in both dairy and plant-based formulations
- Validate ingredient performance under commercial conditions
- Accelerate time to market while reducing formulation risk
Ready to take your UHT product development to the next level? Contact SPX FLOW to explore how our innovation centers and end-to-end solutions can help you overcome formulation challenges and unlock your next breakthrough.