Sensory perception and consumer acceptance of commercial and salt-reduced potato crisps formulated using salt reduction design rules

Successful salt (NaCl) reduction strategies are required to reduce the salt content of snacks while maintaining saltiness perception and consumer acceptance. Previous research suggests that particle physicochemical design rules (small particle size, low density, low hydrophobicity, optimised particle shape) can be leveraged to produce salt particles that enhance saltiness perception. This study aimed to validate these design rules by applying optimised model salts to unsalted potato crisps at a 30% reduced salt content to produce prototype products. A selection of commercial products were also chosen to represent the salt content and crisp style of the broader market, with the aim to investigate the potential of other salt reduction strategies including; direct salt removal without compensation for loss of salt content and increasing time in mouth, while exploring the impact of consumer mouth behaviour type on consumer product preference. Nine products varying in salt content (6 standard, 1 crinkle-cut, 1 thick-cut batch-fried, 1 baked reconstituted potato) were subject to descriptive sensory analysis with a trained panel (n = 11). A subset (seven products) were assessed for consumer acceptance (n = 93). A salt reduction of 30% was achieved while maintaining saltiness perception and consumer acceptance using model salts, while direct removal of salt without perceptual impact was only achievable by 15%. To investigate key drivers of liking, consumers were segmented based on product liking and mouth behaviour. Results suggested that whilst salt content was the primary driver, specific texture profiles were polarising. However, mouth behaviour had minimal influence on preference. These results validate previously described physicochemical design rules for developing novel salt particles for salt reduction and inform ingredient design for the food and flavour industries.