In the food industry, every decision has a direct impact on the profitability of the final product.
The choice of garlic format is no exception: whether in powder, flakes, paste, freeze-dried or extract form, each presentation has a different impact on production costs, yield per kilo, product shelf life and plant operating efficiency.
Understanding how each format of garlic affects the manufacturing process helps to optimise margins, reduce waste and improve overall logistics.
This analysis is particularly relevant for manufacturers of sauces, ready meals, processed meats or vegan products looking to balance functionality, flavour and profitability.
At The Garlic Factory, with over 100 years’ experience as a leading wholesale supplier of industrial garlic, we offer all available formats: garlic powder, garlic paste, garlic flakes, garlic cubes, garlic granules, peeled garlic cloves, garlic extract and black garlic.
In this article, we look at how to choose the most suitable for your production purposes.
Why garlic format influences production costs
Choosing the right garlic format is not just a matter of taste or technical preference: it is a strategic decision that can have a direct impact on unit costs, yield per batch and overall plant efficiency.
Below, we look at the three key factors that make garlic format a significant influence on the final cost of production.
Yield per kilo and dosage according to application
Each garlic format has a different aromatic power and yield per kilo, which directly affects the quantity required per batch and therefore the cost per unit produced:
- Garlic powder and freeze-dried garlic have a high flavour concentration, which allows a low dosage per serving and a higher efficiency per kilo.
- Garlic flakes and garlic cubes provide texture and visual presence, but require larger quantities to achieve the same flavour intensity.
- Garlic paste and garlic extract are homogenous formats ideal for sauces and marinades, with more precise dosing that reduces waste.
For example, 1 kg of garlic powder can yield the equivalent of 4-5 kg of fresh garlic cloves, depending on the final product and recipe.
This equivalence is based on its natural concentration after dehydration: fresh garlic contains 65-80 % water, whereas garlic powder is 100 % dry matter.
According to data from the United States Department of Agriculture (USDA) and industrial manufacturers such as Garlic Company of California, it is estimated that 1 fresh clove is equivalent to 0.8-1 g of powder, and therefore, 1 kg of garlic powder can replace between 1000 and 1250 cloves.
Operational efficiency and compatibility with industrial processes
The format chosen also affects production agility and integration with automated machinery and processes:
- Formats such as garlic powder, garlic granules or garlic paste are ideal for automated lines because of their ease of dosing, mixing and handling.
- Peeled garlic or diced garlic may require manual intervention, which increases operating costs and production times, although they provide value in fresh or artisanal products.
- Freeze-dried garlic is notable for its rapid rehydration and ease of incorporation into dehydrated formulas or long-life foods.
Garlic powder, garlic paste and liquid extract are particularly effective formats in automated industrial environments. Their uniform and stable structure allows for automatic dosing, rapid mixing and reduced machine maintenance, unlike fresh or irregular solid formats such as garlic cubes or peeled cloves.
The right choice of format can reduce production times, avoid line jams and optimise the performance of equipment such as mixers, extruders or automatic filling systems.
Shelf life, transport and storage by format type
Another key factor in the total cost is the shelf life of the product, its specific preservation needs and the costs associated with its transportation:
- Garlic powder, garlic flakes, granules and freeze-dried garlic have a long shelf life, take up less space and do not require refrigeration, which reduces storage and shipping costs.
- Peeled garlic, refrigerated dice or fresh paste require a cold chain, which means higher logistical costs and technical requirements for transport.
- Black garlic and liquid extract require specific packaging, but can be stored at room temperature if well sealed.
Dry products such as garlic powder, garlic flakes, granules or freeze-dried garlic have a long shelf life, do not require a cold chain and take up less space, which reduces logistical costs.
According to the Codex Alimentarius, properly packaged dehydrated foods can be kept in optimal conditions for 12-24 months without refrigeration.
At The Garlic Factory, all our formats are designed to suit the needs of industrial manufacturers, with packaging and preservation options that help minimise overall cost without compromising quality.
Cost comparison between the main industrial garlic formats
The price per kilo of a garlic format does not always reflect its true cost of production.
To make informed decisions, it is essential to analyse the functional cost, i.e. how much the ingredient yields in the final product, and what impact it has on processing, preservation and taste.
Below, we compare the most commonly used formats in the food industry.
Garlic powder vs. garlic paste: uses and associated costs
- Garlic powder is one of the most economical formats in terms of transport, storage and shelf life. It is ideal for use in dry mixes, snacks, seasonings and dehydrated soups. It requires very little quantity to impart flavour, so its yield per kilo is high.
- Garlic paste, on the other hand, offers advantages when a quick integration into doughs, sauces, dressings or ready meals is needed. Its uniform texture reduces mixing times and improves homogeneity, although its cost per kilo is usually higher due to the higher water content and the need for cold storage.
Conclusion: garlic powder is more cost-effective for dry or high volume products. Garlic paste offsets its cost when efficiency is sought in wet or semi-liquid processes.
Freeze-dried vs. flaked garlic: cost-effectiveness and taste
- Freeze-dried garlic is the most expensive format per kilo, but also the one with the highest concentration of flavour and yield. A small amount of rehydrated garlic is equivalent to several cloves of fresh garlic, which reduces the amount needed per recipe. In addition, it preserves the aromatic nuances of natural garlic very well.
- Flaked garlic is more affordable and is mostly used in dehydrated products or mixtures where the ingredient is visually present. It adds texture, but requires a higher dosage to achieve the same intensity of flavour.
Conclusion: freeze-dried garlic is a profitable investment in premium products or high value-added formulas. Flaked garlic is an effective alternative when seeking a balance between functionality, texture and cost.
When to choose garlic cubes, peeled cloves or liquid extract
- Garlic cubes and peeled garlic cloves retain a natural appearance, making them ideal in fresh prepared dishes, side dishes and marinades where the visual presence of the ingredient is key. Their cost per kilo is higher and they require a cold chain.
- Liquid garlic extract is perfect for highly automated production lines, as it is precisely dosed, generates no waste and has a long shelf life. It provides homogenous flavour without altering the texture of the final product.
Conclusion: fresh formats are suitable for applications where the aesthetics of garlic are important. Extract is preferable in standardised formulations where efficiency and cleanliness of the process are paramount.
How to optimise margins according to the chosen format
Beyond the price per kilo, the garlic format has a direct impact on the overall profitability of the production process.
Choosing the right format can make the difference between efficient production and one with wastage, high logistics costs or incompatibility with current market demands.
Below, we explore three key areas where format has a direct impact on margins.
Reducing shrinkage and waste
One of the most important factors in industrial profitability is waste control. More stable industrial garlic formats – such as garlic powder, garlic granules or freeze-dried garlic – allow precise and uniform dosing, which avoids overuse and minimises wastage.
In contrast, fresh formats such as peeled garlic cloves or chilled dice can generate more waste due to oxidation, manual handling or cutting waste, especially if they are not used immediately upon receipt.
More stable garlic formats – such as garlic powder, freeze-dried garlic or granules – allow for precise and uniform dosing, which reduces waste.
In addition, garlic paste allows for faster and more homogenous integration, facilitating dosage control and avoiding batch-to-batch variations(³).
The Garlic Factory supplies each format with clear dosage and performance specifications, helping our customers to optimise usage and reduce losses in each batch.
Savings in logistics and conservation
The format of garlic also determines transport and storage costs, which directly influence the operating margin:
- Dry products such as garlic powder, garlic flakes or freeze-dried garlic do not require refrigeration, have a long shelf life and take up less space, which reduces logistics costs and simplifies storage.
- Fresh or refrigerated formats, such as peeled cloves, cubes or fresh paste, require refrigerated transport and tighter inventory management, which increases the overall cost.
Choosing a format that suits the customer’s logistics infrastructure is key to maintaining profitability throughout the chain.
Adaptation to clean label and automated processes
The clean label trend continues to grow and many brands are looking for functional, natural and consumer-recognisable ingredients.
Some formats such as garlic powder, garlic flakes or black garlic are considered natural ingredients and can be included in clean labels without the need for additives or preservatives.
On the other hand, formats such as garlic paste or liquid extract allow seamless integration into automated processes, reducing production time and improving traceability, which also results in cost savings.
At The Garlic Factory, we help manufacturers select the most cost-effective format not only in terms of price, but also in terms of product positioning, operational efficiency and regulatory compliance.
Conclusion: Choosing the right garlic format to improve profitability
The format of garlic used in food production has an impact far beyond the cost per kilo. It affects the yield of the final product, process efficiency, logistics, product shelf life and ultimately the profit margin.
Choosing the right format – whether garlic powder, garlic paste, garlic flakes, freeze-dried, diced garlic, peeled cloves, extract or black garlic – allows manufacturers to align their industrial processes with their business and quality objectives.
At The Garlic Factory, with over 100 years of experience in the wholesale supply of industrial garlic, we help our customers find the solution that best suits their technical and economic needs.
We offer all formats, with constant availability, 100% Spanish raw material and full technical support to guarantee efficient and profitable production.
Fuentes consultadas
FAO / Codex Alimentarius. General guidelines for dried foods: https://www.fao.org/fao-who-codexalimentarius
Spice House & Garlic Usage Guide. McCormick & Kalsec Technical Sheets.
TechnoFunc – Ingredient Handling in Food Manufacturing: https://technofunc.com