The bottleneck nobody talks about

Drying is the quiet constraint on gummy manufacturing. Starch-based and plant-based gummies typically need 36 to 72 hours in the drying cabinet, and for most producers that cabinet, not the depositor, not the mixer, sets the ceiling on total factory output. Every hour of drying is energy burned, capital tied up and CO₂ emitted.
For manufacturers moving away from gelatin, the problem compounds: matching gelatin’s texture is difficult, and matching its production efficiency has been harder still.

Two routes out

Avebe’s technical experts worked on two routes out.

• PerfectaGEL^® ISET — instant-setting potato starch. Drying from up to 72 hours to as little as 3. The first starch proven in both traditional starch moulding and rigid starchless moulds, and stable across pH, which finally makes fortified vegan gummies practical.
• PerfectaGEL^® FS — add around 1% into your existing recipe. Up to 50% less drying time or temperature. No reformulation, no equipment changes.

“This award recognises an innovation that addresses one of confectionery manufacturing’s biggest hidden challenges. PerfectaGEL^® helps manufacturers reduce drying time, save energy and create new opportunities for plant-based gummies, all without compromising on texture quality.” Marco Overdulve, Sales Manager Food EMEA, Royal Avebe.

Wybren Bakker & Stefan Wessel, Confectionery applications specialists at Avebe.

We are proud to introduce the Avebe Customer Portal (ACP) – an important step in the further digitalization of our customer service.

Through this portal, customers gain a complete and up-to-date overview of their partnership with Avebe, accessible anytime, anywhere.

What’s inside the customer portal:

· Contracts and contract confirmations

· Order, order confirmations and invoices

· Product information and product data sheets

· Direct access to the customer service team

· Latest news and new products

“A digital platform for our customers to manage their business with Avebe 24/7, digital yet personal” says Roger du Croix, Manager Commerce Intelligence & Digitalization.

Learn how clean-label potato starch helps dairy producers increase creaminess, cut costs, and stay sustainable.

Today, consumers want it all when enjoying dairy products like yogurts: a smooth, thick texture, a healthy, sustainable label, and a fair price. However, this means dairy manufacturers are under high pressure to cut costs, reduce waste, and keep labels short and sweet.

But potato starch could be the surprising answer to these challenges. Roy de Vries, Commercial Application Technologist at Avebe, shares his evidence-based insights on how to create dairy products using potato starch that are creamy, clean-label, and cost-effective.

“To meet market needs, we’ve built a texture toolbox based on research that helps us understand and unlock functionality such as creaminess and mouthfeel across a wide variety of dairy applications. Our solution: ETENIA^®, a clean-label, multifunctional, 100% potato starch that behaves like a hydrocolloid with thermo-reversible gelling. This means that the gel melts when heated and sets again when cooled, without losing its texture. It has a neutral taste and appears on a product label simply as potato starch.” Roy says.

ETENIA^® works well in dairy products like:

• Stirred, set, or drinking yogurt
• Puddings, desserts
• Fresh cheese spreads

“Getting mouthfeel right in formulation is one of the biggest challenges in dairy. Through our work in texture science and a broad portfolio of solutions, we’ve identified approaches that consistently deliver consumer-preferred mouthfeel experiences. In our lab tests, we discovered a Greek-style yogurt with 0% fat and 1.5% ETENIA^® nearly doubled creaminess versus a commercial yogurt with 0% fat. And in another trial, a 4%-fat Greek-style yogurt with 1.5% ETENIA^® beat commercial 5% and 10%-fat yogurts on creaminess. The application of ETENIA^® boosts creaminess at low use levels”, Roy shares.

“Consumers want a dairy texture with a full creamy mouthfeel sensation. They’re not really open to changes in texture. Smoothness and creaminess are key drivers of product enjoyment.” Roy continues.

Using potato starch, brands can lower fat content without compromising on decadence, while maintaining the texture customers love and meeting health goals.

Common dairy industry ingredients like butter, cream, and milk regularly fluctuate in price, making cost a main driving factor in the industry.

Therefore, most producers look for ingredients with more stable pricing.

Roy explains, “According to our lab tests in dairy applications:

• 1% ETENIA^® can replace 3% milk fat
• 1% ETENIA^® can replace 1% milk protein
• 1% ETENIA^® can replace 0.5% gelatin”

Replacing hydrocolloids and modified starches, 100% natural potato starch is certainly a sustainable ingredient to use.

”We asked an independent third-party consultant to test the sustainability profile of our products. The results showed that compared to formulas with the same textures, ETENIA^® better reduces total carbon footprint versus gelatin in yogurt applications and milk protein in cream-cheese-type applications.” Roy shares.

Potato starch is a strong water binder and gelling starch that helps reduce syneresis. That means products appear fresh (and not liquid or watery) when customers lift the lid and stay stable until the very last spoonful.

“Plus, ETENIA^® helps yogurts appear bright and white, so the eating experience is pleasant, smooth, and “full-fat” in sensation. That’s because potato starch mimics the behavior of milk fat in the mouth, without adding off notes. This matters for repeat customers, where even tiny textural differences can affect loyalty. A rich, creamy mouthfeel boosts overall liking scores for the end product.” Roy explains.

Operationally, lower syneresis and a more predictable production process help reduce waste and product rework, which in turn improves the overall sustainability of using potato starch.

ETENIA^®’s texture forms after cooling, which is generally within 12 to 24 hours. This prevents mixtures from thickening or clogging during processing and gives manufacturers more freedom with their approach.

“Manufacturers need to forget what they know about typical starches, because ETENIA^® is different. It doesn’t adapt its texture on the line. Instead, it sets cleanly after cooling, which means it fits perfectly into high-temperature dairy processes without creating line issues.

Likewise, with ETENIA^®, manufacturers can achieve their desired product texture by adjusting the use level and the process. To make this practical, we use a suite of solutions built on our benchmark toolbox. These address three recurring challenges in dairy: achieving creaminess, creating the right mouthfeel, and finding the perfect texture. With these tools, producers can fine-tune dosage, optimize preparation, and ensure consistency across processes and applications” says Roy.

For example, here are some texture options:

• Firm yogurt profile
• Creamy Greek-style yogurt
• Spreadable cream cheese

Potato starch gives dairy producers and manufacturers a practical, proven way to maintain an indulgent texture and mouthfeel, along with clean-label, cost control, and sustainability benefits. It raises creaminess at low use levels, replaces more expensive dairy solids, and simplifies processes, all while keeping taste pure and delicious and labels short.

“Potato starch can replace hydrocolloids or modified starches at the same function or even improved functionality. It can replace milk protein or milk fat. It can work in very harsh dairy conditions, in every process setting and can create different textures free-from allergen labeling. If you’re looking for the best protein or fat replacement, or to enhance creaminess in dairy applications, this multifunctional potato starch is one of the purest ingredients you can use.” Roy concludes.

For dairy products, where texture is everything, ETENIA^® transforms common constraints into a competitive advantage.

To learn more about making the switch to ETENIA^® clean-label potato starch, visit our ETENIA product page.

At Avebe, we have been innovating with potato starch since 1919. With over a century of experience in dairy and cheese applications, we understand the complexity of balancing functionality and profitability. “What if you could maintain the taste, texture, and functionality of cheese, while significantly reducing costs?” That question drives our search for smarter, more sustainable solutions in processed cheese. In this blog, Ayse Gürarslan and Roy de Vries share how PerfectaMYL^®, Avebe’s potato starch-based solution for processed cheese, is the answer for the cheese industry.

Market trends & forecasted growth

The global processed cheese market is mature, yet steadily growing. Between 2021 and 2029, volumes are expected to rise from 11,753 tonnes (in 2021)  to 13,021 tonnes in 2025, and ultimately 14,149 tonnes by 2029. Retail remains dominant with 68% market share, but foodservice is catching up, showing consistent growth.

This growth is driven by evolving consumer expectations: affordability, versatility, and premium cheese experiences across applications like burgers, sandwiches, baked goods, and ready meals. Producers are under pressure to deliver on these demands while managing costs and maintaining quality.

Challenges from the producer’s perspective

While market demand is rising, cheese producers face a complex balancing act:

• Cost pressure: Dairy proteins like casein are on average expensive and volatile in price. Producers seek alternatives that reduce costs and dependency without compromising product quality.
• Functionality demands: Cheese must melt, stretch, slice and shred perfectly, especially in foodservice applications where performance is critical.
• Processing efficiency: Manufacturers seek ingredients that integrate smoothly into existing production lines. For example including predictable setting times and minimal stickiness.
• Sustainability goals: There’s a growing trend toward replacing animal-derived ingredients with sustainable, plant-based alternatives that align with environmental and consumer expectations.
• Versatility: Producers require a flexible ingredient system or toolbox capable of adapting to multiple processed cheese formats, from pizza cheese and individually wrapped slices to hard blocks.

Partner with a proven track record

These challenges require more than just an ingredient, they demand a partner with deep technical expertise and a proven track record. Here, Ayse Gürarslan and Roy de Vries, both Customer Application Technologist at Avebe and processed cheese experts, explore in more detail their insights on how to create processed cheese that delivers 100% on the best cheese experience in a cost-effective way.

“We don’t just deliver ingredients,” says Ayse Gürarslan, Customer Application Technologist at Avebe. “We help producers solve different cheese challenges, from cost reduction to shelf-life stability with our solutions that are tested, scalable and backed by decades of expertise. ”

Roy de Vries, Customer Application Technologist at Avebe adds: “ PerfectaMYL^® is more than a starch. It’s a toolbox for different cheeses. We co-create with our customers to make sure every recipe performs, technically and commercially.”

What makes PerfectaMYL^® stand out?

Ayse: “PerfectaMYL^® is a potato starch-based solution that can partially or even largely replace casein in processed cheese. It delivers a powerful combination of functional benefits including excellent meltability (achieved even with high protein replacement of up to 40–78%), stable texture without retrogradation, improved integrity due to reduced stickiness and water migration, high processability, and a neutral taste profile.”

Roy emphasizes that the success of PerfectaMYL^® lies in combining this functionality with expert support.  “The beauty of PerfectaMYL^® is that it’s not just an ingredient, it’s a system. And we help producers integrate it seamlessly into their recipes and processes. We guide customers from pilot to production, offering tailor-made recipes and technical expertise.”

Both experts recognize that today’s challenges require smart, scalable solutions. PerfectaMYL^® offers that flexibility: from slice-on-slice to pizza cheese, from low to high protein replacement, all while preserving taste, structure, and processability.

PerfectaMYL cheese toolbox

Customer challenge

A leading manufacturer of individually wrapped cheese slices was facing rising production costs and quality concerns. Their goal was to reduce reliance on expensive dairy proteins like casein, without compromising the texture, shelf stability, or overall performance of their product. Stickiness between slices and water migration during storage were also causing packaging and quality issues. The company needed a solution that could deliver cost savings and improve product integrity without requiring major changes to their existing recipe or process.

Together with Ayse, Roy explored the potential of PerfectaMYL^® GEL ACT. The team ran trials to test partial casein replacement, focusing on maintaining sensory quality and packaging performance.

“We knew PerfectaMYL^® GEL ACT could do more than just replace protein,” Roy explains.

“It also helps prevent stickiness and water migration, two issues that were really affecting their shelf life.”

By integrating PerfectaMYL^® GEL ACT into their existing formulation, the manufacturer was able to replace 4% of the casein while maintaining the same texture and sensory quality as the original recipe. The solution eliminated stickiness and water migration, improving shelf stability and packaging performance.

Ayse adds: “Most importantly, the company achieved a significant reduction in protein usage saving over €200,000 annually based on their production volume of 1,300 tonnes.” Roy concludes: “It’s a great example of how a small adjustment can have a big impact. And the best part? No compromise on quality.”

Ready to transform your own cheese production?

In a market where functionality has to go hand in hand with profitability PerfectaMYL^® offers a smart, proven solution that meets these demands without compromise.

Consumers expect affordable cheese products that deliver authentic taste, satisfying texture, and reliable functionality. With PerfectaMYL^®, you can deliver exactly that.

Whether you’re looking to improve meltability, streamline your production process, or future-proof your formulations, our experts help you stay ahead of the curve.

If you’d like to discover how PerfectaMYL^® can transform your cheese production, feel free to contact us today for a consultation or sample.

📩 info@avebe.nl

Born in 1993, Iris Bouwers runs a mixed farm together with her parents in Zuidwolde, where she also cultivates starch potatoes for Avebe. She has extensive governance experience, including serving as a councillor for the municipality of De Wolden and as a member of the supervisory board of Agrifirm. From 2019 to 2023, Iris was part of Avebe’s Social Advisory Council.

Marijke Folkers-in ’t Hout, chair of the supervisory board, said: “Iris brings a wealth of knowledge and experience to the supervisory board. Her background as co-owner of an agricultural family business, combined with her supervisory expertise, makes her a valuable addition. We look forward to working with her enthusiastic and committed approach.”

Supervisory board
The supervisory board of Avebe consists of the following nine members: Marijke Folkers-in ’t Hout (Chair), Hans-Wilhelm Giere, Angelique Heckman, Martin Möllering, Robert Smith, Nanne Sterenborg, Hidde van der Wal, Marcel Mensink and Iris Bouwers.

The performance indicator rose to €136.79 per tonne of potatoes, a clear and necessary improvement compared to previous years. The cooperative result after tax is €5.1 million, of which Avebe will pay out €2 million directly to its members. Solvency increased slightly to 36.5%.

Innovation and sustainability
In the 2024/2025 financial year, Avebe invested a total of €60 million. The emphasis of these investments was on making production processes more efficient and sustainable, preventive maintenance, and digitalisation. Fousert: “A great example is the installation of new decanters in Gasselternijveen, which allows us to achieve significant water savings.” Sustainability remains a cornerstone of Avebe’s strategy. Ambitious targets have been set for 2030: a 30% reduction in CO2 emissions (scope 1 and 3), a 1.5% annual improvement in energy efficiency, and a significant reduction in water extraction. Avebe reports on its sustainability goals in line with the forthcoming European CSRD requirements.

Product innovations
The financial year was further characterised by strong product innovations, such as the launch of PerfectaMAR^®, a unique application of potato protein in surimi, which offers especially good growth prospects in Asia. “We are continuing this line. Alongside protein innovation, we are constantly investing in the development of potato starch. This year, we have developed a vegan alternative to gelatin in vitamin gummies, and a plant-based alternative to gelatin in liquorice, wine gums and other confectionery using PerfectaGEL^®. Our innovative potato starch significantly reduces drying time compared to gelatin or pectin, leading to more efficient production processes and lower energy costs,” said Fousert.

Market developments
Fousert paid particular attention to the current market situation: due to a larger growing area, an early harvest, and high yields, the supply of starch potatoes in Europe has increased considerably this season. Fousert commented, “At the same time, the cost price and risks for potato cultivation continue to rise, and we see increasing uncertainty and geopolitical tensions worldwide. To keep cultivation attractive for our members, returns will need to keep pace with these developments.” According to the CEO, agility and entrepreneurship remain essential to respond to changing market conditions and achieve sustainable growth. “Avebe is well positioned to work with its members and partners to make the supply chain future-proof and seize opportunities in new markets. The acquisition of flake and granule producer Solan in Poland is a good example of this,” Fousert concluded.

We’re proud to announce that Avebe has been nominated for the prestigious Fi Award in the Plant-based Innovation category with our innovation: PerfectaGEL^® FS!  

PerfectaGEL^® FS speeds up drying time in confectionery while maintaining a nice texture. A true solution that delivers both efficiency and indulgence.  

Adding just a small amount of PerfectaGEL^® can significantly improve the production process of starch-based gummies:

• Reduce drying time by up to 50%
• Faster setting thanks to a unique modification that enables gelling without compromising quality
• Produce more tasty vegan gummies with improved texture and sustainability
• Lower energy costs and a more sustainable production process

 This nomination recognises our team’s dedication and our commitment to sustainable and plant-based innovation.  

On Monday 1st December, we’ll present our solution to the jury during the judging day.   

Visit our booth 40H110 (Hall: H4.0) at Fi Europe in Paris, taste and discover why PerfectaGEL^® is shaping the future of food innovation! 

Struggling to achieve the perfect indulgent taste and texture in your confectionery? As the demand for more natural, delicious treats rises, balancing taste, texture, and affordability can be tricky.

In the world of sugar confectionery, indulgence is king — people want to feel instant and intense satisfaction from the products they choose.

To deliver on such pleasurable promises though, a product’s taste and texture needs to be just right. Beyond this, producers need to find a way to keep products affordable, while also accommodating the latest consumer trends. Such as the growing demand for more animal-free, natural confectionery ingredients.

Ticking all of these boxes can feel like a never-ending challenge for confectionery producers. Because unfortunately, every ingredient has it’s pros and cons in terms of texture or processing. Particularly, achieving impressive textures and flavours with alternative ingredients, and delivering such products at scale is not easy.

If producers are serious about appealing to the sweet tooths of tomorrow, they will need to find natural confectionery ingredients that push customer’s indulgence buttons in all the right ways.

Here, Stefan Wessel, Customer Application Specialist at Avebe, explores this issue in more detail and shares his insights on how to create confectionery that delivers 100% indulgence in a more natural, affordable way

One of the biggest challenges is the volatile cost of traditional gelling agents like gelatin and gum arabic. For many years, these ingredients have been used to create the chewiness, elasticity, and stability that consumers crave in confectionery products. But for various reasons — fluctuating supply chains and increased demand from other industries to name a couple — prices are unstable. Producers are finding it harder to maintain cost efficiency.

And although consumers are increasingly demanding more plant-based confectionery ingredients, substituting such ingredients for the costly traditional gelling agents isn’t always very simple. Achieving the right balance of firmness and chewiness in plant-based gummies, jellies and pastilles can be challenging. Gelatin tends to provide that unique ‘elastic texture, which can be very difficult to replicate with plant-based ingredients. That’s also why there is a large category of hybrids. Gum Arabic plays a crucial role in stabilizing certain confectionery coatings and fillings. Finding an alternative that performs just as well without introducing unwanted processing challenges is not always straightforward.

As an added challenge, sometimes when a viable solution does present itself, misconceptions about its attributes can prevent producers from embracing it. For example, although starch-based alternatives require certain processing adaptations, new developments and innovations in both ingredients and textures are ensuring that such adaptations are an ever more attractive option.

One such cutting-edge starch-based innovation is PerfectaGEL^®. And as the industry navigates numerous challenges moving forward, PerfectaGEL^® provides some real game-changing advantages.

PerfectaGEL^® is a key brand for confectionery potato starches we’ve developed at Royal Avebe.

When it comes to creating cost-effective (vegan) sugar confectionery without compromising on taste and texture, PerfectaGEL^® starches are the ultimate solution. By offering the following advantages, these solutions enable maximum indulgence, multiple textures with minimum cost and processing advantages.

PerfectaGEL^® starches offer great taste and texture as a cheaper alternative to gelatin and pectin. In addition, some PerfectaGEL^® starches have fast-setting properties and low viscosity, allowing producers to reduce energy costs or increase factory output by up to 50%. Safe to say that a boost in efficiency like this will inevitably facilitate much more competitive product pricing.

Crucially, this cost-effectiveness does not come at the expense of quality. PerfectaGEL^® also consistently achieves the firmness, chewiness, and elasticity consumers expect in premium confectionery. So the end-user gets all the indulgence they crave in an affordable, sustainable, natural, (more) plant-based way.

PerfectaGEL^® starches make all of this possible without any added hassle for the producer. With easy-to-use drop-in solutions, it integrates seamlessly into existing production processes, requiring no new equipment for producers that are already used to making starch-based gummies. Although for some gelatin producers, new equipment might be necessary.

All-in-all, if used correctly, PerfectaGEL^® can help producers stay competitive in an ever-evolving industry.

As well as the common confectionery challenges I’ve already discussed, PerfectaGEL^® also helps producers align their products with other important trends that are re-shaping the industry.

There is a growing demand for sustainable and ethically sourced ingredients. Both individual consumers and businesses are starting to scrutinise supply chains more closely, and are favouring confectionery ingredients that have a lower environmental impact. Neither gelatin, which relies on animal-derived raw materials, nor gum arabic, which is linked to concerns around deforestation and unstable supply chains, really align with this growing demand. PerfectaGEL^® however, as a plant-based, starch-derived solution, offers a more sustainable and ethical supply chain. This is because potatoes are a widely available, renewable crop, with a relatively low environmental impact.

In a nutshell, consumers increasingly want natural, sustainable, (vegan) confectionery treats that still taste incredible, and don’t break the bank. If producers can deliver all those things in one package, they will more than compete; they will stand out.

But don’t take my word for it. Have a look at the case study below, and you’ll see how effective PerfectaGEL^® can be:

Just a few months ago, a renowned confectionery producer was having to cope with long drying times for their starch-based gummies, limiting their production capacity. Their energy costs were too high, and factory output was down due to the increased drying time compared to the gelatin gummies they used to make. As a result, the company was looking for a way to reduce drying time without making investments in the production process. They also wanted to achieve a firmer texture in their gummies, without having to change the recipe.

By adding PerfectaGEL^® FS on top of their current recipe, the company was able to reduce drying time by 25%. This allowed them to simultaneously increase factory output, and lower energy costs per gummy. While also producing firmer, more sustainable gummies.

In an evolving confectionery market where cost-efficiency, sustainability, and product quality are more important than ever, PerfectaGEL^® offers a natural solution that can meet these demands without compromise.

Consumers want — and deserve — a way to indulge in delicious tastes and textures that give them a real sense of satisfaction. With PerfectaGEL^®, you can provide that for them.

Whether you’re looking to enhance texture, streamline production, or future-proof your formulations, PerfectaGEL^® can help you stay ahead of the curve.

If you’d like to discover how PerfectaGEL^® can transform your own confectionery production, please feel free to contact me today for a consultation or sample.

Synthetic adhesives are non-biodegradable and complicate recycling

Packaging, especially food packaging, consists of more than fiber alone. Adhesives keep the packaging together and hold tamper-proof seals in place. These adhesives need to be food-safe and, depending on the contents, serve as barriers to oil, fat, volatile organic compounds (VOCs) and oxygen.

Between 40 and 50 percent of all food packaging relies on hotmelt adhesives. Developed in the 1940s, synthetic polymers such as ethylene-vinyl acetate (EVA), polyolefins and styrene block copolymers (SBCs) form strong, fast-setting and cost-effective bonds. Unfortunately, these tried-and-tested synthetic adhesives are non-biodegradable and complicate recycling.

What is PerfectaCOL^®?

PerfectaCOL^® GM is a potato starch-based adhesive designed to meet the demanding needs of dry food packaging. It’s heat-pressure sealable and an oil-and-grease barrier. This versatility, makes it a viable alternative to synthetic heat-pressure sealable adhesives and even hotmelts, and the perfect solution for ensuring product integrity and sustainability.

Benefits of PerfectaCOL^®

• Heat-Pressure Sealability: Achieves strong, consistent seals at lower temperatures, reducing energy use by up to 20%. Also suitable as an alternative to some hotmelts.
• Oil-and-Grease Resistance: Maintains barrier performance even in high-fat applications, eliminating the need for synthetic coatings.
• Biodegradable: Fully compostable and biodegradable, free from harmful additives.
• PFAS-Free, ensures environmental integrity by avoiding harmful chemicals.
• Bio-Based: Potato starch is a natural, renewable resource that fully aligns with consumer demand for eco-friendly packaging.

The shift toward sustainable packaging accelerates

The factory in Gasselternijveen was the first to start processing. The location in Ter Apelkanaal will follow next week, as will the German factories in Dallmin and Lüchow.

Planting conditions and the growing season were generally favourable this year. The crops are therefore looking good.