BBQ formulation challenges with scalable ingredient solutions

As the summer BBQ season heats up, food developers are being challenged to deliver products that combine bold, memorable flavors with clean-label credentials and high-performance formulations that can withstand the intensity of the grill—literally. From steaks to sauces, the BBQ is a proving ground where taste, texture, and technical resilience are put to the ultimate test.

The BBQ Challenge

Grilling exposes products to high heat, open flames, and extended holding times. To succeed, developers must work with binding systems that hold firm, emulsifiers that remain stable, and flavor components that retain their impact under stress. At Brenntag Application Kitchen in Allentown, USA, they have tackled these challenges with innovative ingredient systems that are clean, scalable, and compliant with regional regulations.

Plant-Based With Meat-Like Performance
Flexitarian grilling continues to gain ground, but achieving the bite, browning, and juiciness of meat in plant-based products—without artificial binders—remains a complex task. Brenntag's approach blends pea and soy proteins, native starches, and natural emulsifiers to replicate meat-like performance.

One standout example is its clean-label Tex-Mex Sauce, which uses pea protein for emulsification and body, delivering a creamy, spicy finish that’s perfect for burger builds. Brenntag also craft grill-stable flavor systems using yeast extracts, natural umami enhancers, and aromatics for authentic sensory experiences.

Clean-Label Sausages Without Compromise

With consumer demand growing for nitrite- and phosphate-free sausages, they’ve developed solutions using natural antimicrobials for shelf life, celery powder for color and preservation, and functional flavorings without e-numbers. These innovations maintain juiciness, safety, and flavor in heat-processed sausage formats.

Better-for-You BBQ

Health-conscious BBQ concepts are proving that grilled foods can be both indulgent and better for you. From sodium-reduced seasoning blends to lean meat formulations and fat-reduced systems, we provide technical solutions that allow reformulation without sacrificing taste, texture, or clean-label transparency.

Sauces That Do More

Sauces are not just condiments—they’re a central part of the eating experience. Brenntag scalable, clean-label sauces are built on natural emulsifiers, heat-stable flavor carriers, and plant-based thickeners.
An example is its Korean-style sauce: sweet, smoky, and umami-rich, crafted without artificial smoke flavorings. Designed for commercial scalability, it blends yeast extract with natural sweeteners for bold flavor and consumer-friendly appeal.

The Future of BBQ Innovation

Whether it’s delivering meat-like plant-based products, cleaner sausages, better-for-you grilled items, or multi-functional sauces, their focus remains the same: bold flavor, clean labels, and formulations that can stand the heat. This summer, the BBQ is not just a meal—it’s a showcase for the future of food innovation.