Mass Reduction: The Weighty Challenge for Exploration Space Flight

Meeting nutritional and acceptability requirements is critical for the food system for an exploration class space mission. However, this must be achieved within the constraints of available resources such as water, crew time, stowage volume, launch mass and power availability.  Due to resource constraints, exploration class missions are not expected to have refrigerators or freezers for food storage, and current per person food mass must be reduced to improve mission feasibility.  The Packaged Food Mass Reduction Trade Study (Stoklosa, 2009) concluded that the mass of the current space food system can be effectively reduced by decreasing water content of certain foods and offering nutrient dense substitutes, such as meal replacement bars and beverages. Target nutrient ranges were established based on the nutritional content of the current breakfast and lunch meals in the ISS standard menu. A market survey of available commercial products produced no viable options for meal replacement bar or beverage products. New prototypes for both categories were formulated to meet target nutrient ranges. Samples of prototype products were packaged in high barrier packaging currently used for ISS and underwent an accelerated shelf life study at 31 degC and 41 degC (50% RH) for 24 weeks. Samples were assessed at the following time points: Initial, 6 weeks, 12 weeks, and 24 weeks. Testing at each time point included the following: color, texture, water activity, acceptability, and hexanal analysis (for food bars only). Proof of concept prototypes demonstrated that meal replacement food bars and beverages can deliver a comparable macronutrient profile while reducing the overall mass when compared to the ISS Standard Menu. Future work suggestions for meal replacement bars: Reformulation to include ingredients that reduce hardness and reduce browning to increase shelf life. Micronutrient analysis and potential fortification. Sensory evaluation studies including satiety tests and menu fatigue. Water Intake Analysis: The water in thermostabilized foods is considered as part of a crewmember's daily water intake. Extensive meal replacement would require further analyses to determine if additional water provisioning would be required per crewmember negating some of the mass savings.