10/08/2026
Sugar reduction is one of the most common reformulation briefs we see, and it is also one of the most underestimated.
The reason is that sugar is doing far more in a product than making it taste sweet.
โ It is bulk. In a powder or a bar, sugar occupies real physical volume. Take it out and the whole formula has to be rebalanced, which changes the percentage every other ingredient represents, including your premix.
โ It affects water activity. Sugar binds water. Remove it and free water in the system can rise, which speeds up degradation of moisture-sensitive nutrients and raises caking risk in dry blends.
โ It carries flavor. Sweetness masks a lot. Minerals bring metallic notes, some B vitamins bring bitterness, and once the sugar comes down those notes step forward.
โ It changes texture and processing. Sugar affects viscosity, crystallization, browning and how material flows through equipment.
โ High intensity sweeteners do not fill the gap physically. They replace sweetness at a tiny inclusion rate, so you still need a bulking agent, and that choice interacts with everything above.
The practical takeaway is that a sugar reduction project is a fortification project whether anyone planned it that way. Your overages were calculated against the old matrix, and the new one behaves differently.
The teams that get this right bring the premix conversation in at the start of the reformulation rather than at the end of it.
Have you run a sugar reduction that moved more than you expected? ๐