How Methylcellulose Keeps Fillings Intact & Cuts Costs in Mozzarella Sticks

Filling Blowout in Pastry & Mozzarella Sticks

A frozen snack manufacturer, known for their premium mozzarella sticks and stuffed appetizers, was struggling with a frustrating and persistent issue. Despite using high-quality ingredients, they kept experiencing filling blowout during frying and baking.

They had tried almost everything to resolve this issue, but nothing seemed to be working. They tested different stabilizing ingredients, but none were strong enough to keep their fillings intact during high-heat cooking. Some stabilizers didn’t hold up at high temperatures, while others ruined the texture and meltability of the cheese. They even tried adjusting their processing techniques and investing in new machinery in hopes of fixing the issue, but filling blowout persisted. Customers noticed cheese leakage and were upset about messy and inconsistent products and a disappointing eating experience.

Cheese Reduction in Mozzarella Sticks Using Methylcellulose

On top of that, they had another issue: rising dairy costs and increasing demand for lower-fat, cost-effective formulations. They needed a solution that would allow them to reduce cheese content in their mozzarella sticks while maintaining the creamy, stretchy texture that made their product popular. The company needed a way to cut costs without sacrificing quality.

After being fed up with wasting time and money on trial-and-error solutions, they decided it was time to get some outside guidance from Think Ingredients.

The Solution: How Methylcellulose Solved Both Problems

Luckily for them, we had just the solution that could tackle both challenges at once: methylcellulose.

Known for its thermally reversible gelation properties, methylcellulose’s unique functionality makes it the ideal choice for stabilizing fillings, reducing cheese content, and improving product consistency. This all-in-one solution could help prevent filling blowout while also allowing the company to reduce cheese content. To ensure the best results, we worked closely with their team to determine the best grade of methylcellulose for their application, as well as guide them through the reformulation process.

Graph depicting the thermally reversible gel strength for MCE 100TS, 250T and 4000 at various temperatures.

The Results: Methylcellulose Keeps Pastry Fillings Intact & Cuts Costs

By incorporating methylcellulose into their formulation, the manufacturer successfully eliminated filling blowout during frying and baking. When exposed to high temperatures, methylcellulose formed a strong, heat-stable gel, keeping filling intact and preventing leakage throughout the cooking process. Once the product cooled, the gel returned to its original viscosity, allowing for a smooth, creamy texture without affecting eating experience. Unlike traditional stabilizers that break down under high heat, methylcellulose remained effective even in high-moisture fillings.

Beyond solving their filling blowout issue, methylcellulose also helped the manufacturer reduce cheese content without sacrificing texture. By mimicking the stretchiness and mouthfeel of cheese, methylcellulose provided the same creamy experience consumers expected—even with 15% less cheese. This lowered ingredient costs while allowing the company to maintain the premium quality of their mozzarella sticks.

With just one ingredient, they were able to keep pastry fillings intact & cut costs in mozzarella sticks. The company was able to improve cost efficiency, and enhance overall product performance—all while ensuring their customers continued to enjoy the high-quality taste and texture they love.

🎥 See how it works:

Another Methylcellulose Success: Smoother Production, Happier Customers

With the new formulation in place, the company saw immediate improvements—not just in the product, but in their entire process. They were able to streamline production, cutting down on the need for frequent adjustments and minimizing ingredient waste. The team saved time, saved resources, and could operate more efficiently, all while delivering consistent, high-quality products.

President of the company shared:

" Think Ingredients completely transformed our mozzarella sticks. We no longer have filling blowout problems, and successfully reduced cheese without sacrificing texture or taste. It was an approach we hadn't even thought of, and we’re thrilled that their expertise saved us money while keeping our customers happy."

The improved consistency and cost efficiency led to increased customer satisfaction, helping the company strengthen its market position.

Let’s Think Differently About Formulations

At Think Ingredients, we love helping our customers find creative solutions to their formulation challenges. Whether you're dealing with blowouts in fillings or looking for ways to improve product texture, we’re here to help.

We are a proud distributor of SE Tylose methylcellulose and HPMC products for food applications in Canada.

Contact us and see how we can help you achieve success in your formulations.

How Methylcellulose Keeps Pastry Fillings Intact