Fast Food Nation: What The All-American Meal is Doing to the World (17 page)

Although flavors usually arise from a mixture of many different volatile chemicals, a single compound often supplies the dominant aroma. Smelled alone, that chemical provides an unmistakable sense of the food. Ethyl-2-methyl butyrate, for example, smells just like an apple. Today’s highly processed foods offer a blank palette: whatever chemicals you add to them will give them specific tastes. Adding methyl-2-peridylketone makes something taste like popcorn. Adding ethyl-3-hydroxybutanoate makes it taste like marshmallow. The possibilities are now almost limitless. Without affecting the appearance or nutritional value, processed foods could even be made with aroma chemicals such as hexanal (the smell of freshly cut grass) or 3-methyl butanoic acid (the smell of body odor).

The 1960s were the heyday of artificial flavors. The synthetic versions of flavor compounds were not subtle, but they did not need to be, given the nature of most processed food. For the past twenty years food processors have tried hard to use only “natural flavors” in their products. According to the FDA, these must be derived entirely from natural sources — from herbs, spices, fruits, vegetables, beef, chicken, yeast, bark, roots, etc. Consumers prefer to see natural flavors on a label, out of a belief that they are healthier. The distinction between artificial and natural flavors can be somewhat arbitrary and absurd, based more on how the flavor has been made than on what it actually contains. “A natural flavor,” says Terry Acree, a professor of food science at Cornell University, “is a flavor that’s been derived with an out-of-date technology.” Natural flavors and artificial flavors sometimes contain exactly the same chemicals, produced through different methods. Amyl acetate, for example, provides the dominant note of banana flavor. When you distill it from bananas with a solvent,
amyl acetate is a natural flavor. When you produce it by mixing vinegar with amyl alcohol, adding sulfuric acid as a catalyst, amyl acetate is an artificial flavor. Either way it smells and tastes the same. The phrase “natural flavor” is now listed among the ingredients of everything from Stonyfield Farm Organic Strawberry Yogurt to Taco Bell Hot Taco Sauce.

A natural flavor is not necessarily healthier or purer than an artificial one. When almond flavor (benzaldehyde) is derived from natural sources, such as peach and apricot pits, it contains traces of hydrogen cyanide, a deadly poison. Benzaldehyde derived through a different process — by mixing oil of clove and the banana flavor, amyl acetate — does not contain any cyanide. Nevertheless, it is legally considered an artificial flavor and sells at a much lower price. Natural and artificial flavors are now manufactured at the same chemical plants, places that few people would associate with Mother Nature. Calling any of these flavors “natural” requires a flexible attitude toward the English language and a fair amount of irony.

The small and elite group of scientists who create most of the flavor in most of the food now consumed in the United States are called “flavorists.” They draw upon a number of disciplines in their work: biology, psychology, physiology, and organic chemistry. A flavorist is a chemist with a trained nose and a poetic sensibility. Flavors are created by blending scores of different chemicals in tiny amounts, a process governed by scientific principles but demanding a fair amount of art. In an age when delicate aromas, subtle flavors, and microwave ovens do not easily coexist, the job of the flavorist is to conjure illusions about processed food and, in the words of one flavor company’s literature, to ensure “consumer likeability.” The flavorists with whom I spoke were charming, cosmopolitan, and ironic. They were also discreet, in keeping with the dictates of their trade. They were the sort of scientist who not only enjoyed fine wine, but could also tell you the chemicals that gave each vintage its unique aroma. One flavorist compared his work to composing music. A well-made flavor compound will have a “top note,” followed by a “dry-down,” and a “leveling-off,” with different chemicals responsible for each stage. The taste of a food can be radically altered by minute changes in the flavoring mix. “A little odor goes a long way,” one flavorist said.

In order to give a processed food the proper taste, a flavorist must always consider the food’s “mouthfeel” — the unique combination of textures and chemical interactions that affects how the flavor is perceived.
The mouthfeel can be adjusted through the use of various fats, gums, starches, emulsifiers, and stabilizers. The aroma chemicals of a food can be precisely analyzed, but mouthfeel is much harder to measure. How does one quantify a french fry’s crispness? Food technologists are now conducting basic research in rheology, a branch of physics that examines the flow and deformation of materials. A number of companies sell sophisticated devices that attempt to measure mouthfeel. The TA.XT2i Texture Analyzer, produced by the Texture Technologies Corporation, performs calculations based on data derived from as many as 250 separate probes. It is essentially a mechanical mouth. It gauges the most important rheological properties of a food — the bounce, creep, breaking point, density, crunchiness, chewiness, gumminess, lumpiness, rubberiness, springiness, slipperiness, smoothness, softness, wetness, juiciness, spreadability, spring-back, and tackiness.

Some of the most important advances in flavor manufacturing are now occurring in the field of biotechnology. Complex flavors are being made through fermentation, enzyme reactions, fungal cultures, and tissue cultures. All of the flavors being created through these methods — including the ones being synthesized by funguses — are considered natural flavors by the FDA. The new enzyme-based processes are responsible for extremely lifelike dairy flavors. One company now offers not just butter flavor, but also fresh creamy butter, cheesy butter, milky butter, savory melted butter, and super-concentrated butter flavor, in liquid or powder form. The development of new fermentation techniques, as well as new techniques for heating mixtures of sugar and amino acids, have led to the creation of much more realistic meat flavors. The McDonald’s Corporation will not reveal the exact origin of the natural flavor added to its french fries. In response to inquiries from
Vegetarian Journal
, however, McDonald’s did acknowledge that its fries derive some of their characteristic flavor from “animal products.”

Other popular fast foods derive their flavor from unexpected sources. Wendy’s Grilled Chicken Sandwich, for example, contains beef extracts. Burger King’s BK Broiler Chicken Breast Patty contains “natural smoke flavor.” A firm called Red Arrow Products Company specializes in smoke flavor, which is added to barbecue sauces and processed meats. Red Arrow manufactures natural smoke flavor by charring sawdust and capturing the aroma chemicals released into the air. The smoke is captured in water and then bottled, so that
other companies can sell food which seems to have been cooked over a fire.

In a meeting room at IFF, Brian Grainger let me sample some of the company’s flavors. It was an unusual taste test; there wasn’t any food to taste. Grainger is a senior flavorist at IFF, a soft-spoken chemist with graying hair, an English accent, and a fondness for understatement. He could easily be mistaken for a British diplomat or the owner of a West End brasserie with two Michelin stars. Like many in the flavor industry, he has an Old World, old-fashioned sensibility which seems out of step with our brand-conscious, egocentric age. When I suggested that IFF should put its own logo on the products that contain its flavors — instead of allowing other brands to enjoy the consumer loyalty and affection inspired by those flavors — Grainger politely disagreed, assuring me such a thing would never be done. In the absence of public credit or acclaim, the small and secretive fraternity of flavor chemists praises one another’s work. Grainger can often tell, by analyzing the flavor formula of a product, which of his counterparts at a rival firm devised it. And he enjoys walking down supermarket aisles, looking at the many products that contain his flavors, even if no one else knows it.

Grainger had brought a dozen small glass bottles from the lab. After he opened each bottle, I dipped a fragrance testing filter into it. The filters were long white strips of paper designed to absorb aroma chemicals without producing off-notes. Before placing the strips of paper before my nose, I closed my eyes. Then I inhaled deeply, and one food after another was conjured from the glass bottles. I smelled fresh cherries, black olives, sautéed onions, and shrimp. Grainger’s most remarkable creation took me by surprise. After closing my eyes, I suddenly smelled a grilled hamburger. The aroma was uncanny, almost miraculous. It smelled like someone in the room was flipping burgers on a hot grill. But when I opened my eyes, there was just a narrow strip of white paper and a smiling flavorist.

AT THE HEIGHT OF
the potato harvest, I visited the Lamb Weston plant in American Falls, Idaho. It’s one of the biggest fry factories in the world and makes french fries for McDonald’s. It has a production capacity more than three times larger than that of the Simplot plant in
Aberdeen. It is a state-of-the-art processing facility where raw commodities and man-made additives are combined to make America’s most popular food.

Lamb Weston was founded in 1950 by F. Gilbert Lamb, the inventor of a crucial piece of french fry-making technology. The Lamb Water Gun Knife uses a high-pressure hose to shoot potatoes at a speed of 117 feet per second through a grid of sharpened steel blades, thereby creating perfectly sliced french fries. After coming up with the idea, Gil Lamb tested the first Water Gun Knife in a company parking lot, shooting potatoes out of a fire hose. Lamb sold his company to ConAgra in 1988. Lamb Weston now manufactures more than 130 different types of french fries, including: Steak House Fries, CrissCut Fries, Hi-Fries, Mor-Fries, Burger Fries, Taterbabies, Taterboy Curley QQQ Fries, and Rus-Ettes Special Dry Fry Shoestrings.

Bud Mandeville, the plant manager, led me up a narrow, wooden staircase inside one of the plant’s storage buildings. On the top floor, the staircase led to a catwalk, and beneath my feet I saw a mound of potatoes that was twenty feet deep and a hundred feet wide and almost as long as two football fields. The building was cool and dark, kept year-round at a steady 46 degrees. In the dim light the potatoes looked like grains of sand on a beach. This was one of seven storage buildings on the property.

Outside, tractor-trailers arrived from the fields, carrying potatoes that had just been harvested. The trucks dumped their loads onto spinning rods that brought the larger potatoes into the building and let the small potatoes, dirt, and rocks fall to the ground. The rods led to a rock trap, a tank of water in which the potatoes floated and the rocks sank to the bottom. The plant used water systems to float potatoes gently this way and that way, guiding different sizes out of different holding bays, then flushing them into a three-foot-deep stream that ran beneath the cement floor. The interior of the processing plant was gray, massive, and well-lit, with huge pipes running along the walls, steel catwalks, workers in hardhats, and plenty of loud machinery. If there weren’t potatoes bobbing and floating past, you might think the place was an oil refinery.

Conveyer belts took the wet, clean potatoes into a machine that blasted them with steam for twelve seconds, boiled the water under their skins, and exploded their skins off. Then the potatoes were pumped into a preheat tank and shot through a Lamb Water Gun Knife. They emerged as shoestring fries. Four video cameras scrutinized
them from different angles, looking for flaws. When a french fry with a blemish was detected, an optical sorting machine time-sequenced a single burst of compressed air that knocked the bad fry off the production line and onto a separate conveyer belt, which carried it to a machine with tiny automated knives that precisely removed the blemish. And then the fry was returned to the main production line.

Sprays of hot water blanched the fries, gusts of hot air dried them, and 25,000 pounds of boiling oil fried them to a slight crisp. Air cooled by compressed ammonia gas quickly froze them, a computerized sorter divided them into six-pound batches, and a device that spun like an out-of-control lazy Susan used centrifugal force to align the french fries so that they all pointed in the same direction. The fries were sealed in brown bags, then the bags were loaded by robots into cardboard boxes, and the boxes were stacked by robots onto wooden pallets. Forklifts driven by human beings took the pallets to a freezer for storage. Inside that freezer I saw 20 million pounds of french fries, most of them destined for McDonald’s, the boxes of fries stacked thirty feet high, the stacks extending for roughly forty yards. And the freezer was half empty. Every day about a dozen railroad cars and about two dozen tractor-trailers pulled up to the freezer, loaded up with french fries, and departed for McDonald’s restaurants in Boise, Pocatello, Phoenix, Salt Lake City, Denver, Colorado Springs, and points in between.

Near the freezer was a laboratory where women in white coats analyzed french fries day and night, measuring their sugar content, their starch content, their color. During the fall, Lamb Weston added sugar to the fries; in the spring it leached sugar out of them; the goal was to maintain a uniform taste and appearance throughout the year. Every half hour, a new batch of fries was cooked in fryers identical to those used in fast food kitchens. A middle-aged woman in a lab coat handed me a paper plate full of premium extra longs, the type of french fries sold at McDonald’s, and a salt shaker, and some ketchup. The fries on the plate looked wildly out of place in this laboratory setting, this surreal food factory with its computer screens, digital readouts, shiny steel platforms, and evacuation plans in case of ammonia gas leaks. The french fries were delicious — crisp and golden brown, made from potatoes that had been in the ground that morning. I finished them and asked for more.