OPENFUEL
Open-Source Endurance Fuel
Category

Carbohydrate Gels

Concentrated carbohydrate delivery in a single sachet. Designed for endurance fueling during events lasting 1–4 hours, with rapid intestinal oxidation via multi-transportable carbohydrate pathways.

Gels allow precise, modular carbohydrate stacking: one gel every 20–30 minutes delivers 60–90 g/h when taken consistently. They're the most portable fueling format, but osmolality management (always chase with water) is non-negotiable.

Key Formulation Principles

Every ingredient decision in a carbohydrate gel traces back to one of four core principles.

1

Multi-Transportable Carbohydrates

Intestinal glucose absorption is limited to ~60 g/h via the SGLT-1 co-transporter. Adding fructose (absorbed via GLUT-5) unlocks a separate pathway, enabling total oxidation rates of 90–120 g/h. The optimal glucose-equivalent to fructose ratio is approximately 1:0.8, achieved here via maltodextrin and crystalline fructose.

2

30 g Carbs per Sachet for Modular Stacking

A 30 g target allows clean arithmetic for race planning. Two gels per hour = 60 g/h. Three per hour = 90 g/h. Athletes can dial intake to their individual carbohydrate tolerance and event duration without fractional dosing. Sachets are standardised at 40 g total weight (including water, electrolytes, and texture agents).

3

Acidic pH for Safety and Preservation

A finished gel pH at or below 4.6 classifies the product as an “acidified food” under FDA and Codex standards, significantly inhibiting pathogen growth. Citric acid drives pH to ~3.8–4.2 in the MTC-30 formula. Potassium sorbate provides backup protection against yeast and mould at 0.1% use level.

4

Osmolality: Hypertonic by Design — Chase with Water

An undiluted 40 g gel sits at ~1,200 mOsm/kg — well above isotonic (~290 mOsm/kg). This is by design: a high carbohydrate density in a small sachet is the whole point of a gel. Consuming 150–250 mL of water alongside dilutes the bolus to near-isotonic conditions in the stomach, supporting gastric emptying and absorption.

Research-Backed Targets

These ranges are derived from the current meta-analytic evidence base, not marketing specs.

Carbs/serving

20–30 g

Stackable to 60–120 g/h

Carb Ratio

1:0.8

Glucose eq : Fructose

Sodium

150–250 mg

Per serving

Potassium

40–80 mg

Per serving

pH Target

≤4.6

Acidified food classification

Evidence Sources

Jeukendrup et al. (2004) — Multiple transportable carbohydrates and oxidation rates; SGLT-1 saturation at ~60 g/h glucose equivalent.

Rowlands et al. (2015 meta-analysis) — 1:0.8 glucose:fructose ratio consistently outperforms 2:1 at intakes above 60 g/h.

Pfeiffer et al. (2010) — GI tolerance of high-fructose formulas; gut training protocols and their effect on fructose malabsorption.

EFSA (2012) — Scientific opinion on carbohydrate-electrolyte solutions; osmolality and sodium concentration targets.

Recommended Formula

The MTC-30 Gel is the reference formula for this category. Every ingredient is listed with its role and evidence rating.

Carbohydrate Gelv1.0
88/100

MTC-30 Gel

A 30 g/serving carbohydrate gel built on a 1:0.8 maltodextrin-to-fructose ratio, delivering multi-transportable carbohydrates with a moderate sodium load optimised for 1–3 hour efforts.

Carbs / serving30g
Sodium200mg
Carb ratio1:0.8
Est. cost$0.12
high-carbmulti-transportablerace-daygel

Ingredient Breakdown — MTC-30 Gel (per 40 g sachet)

IngredientAmountRoleEvidence
Maltodextrin DE 10-1516.7 gPrimary carbohydrate — glucose-transporter substrateHigh evidence
Fructose13.3 gSecondary carbohydrate — GLUT-5 transporter substrateHigh evidence
Sodium Citrate Dihydrate450 mgElectrolyte / alkalising bufferModerate evidence
Sodium Chloride240 mgElectrolyte / osmolality tuningHigh evidence
Potassium Chloride100 mgElectrolyte — potassium replacementModerate evidence
Citric Acid150 mgpH adjustment / flavourFunctional
Xanthan Gum80 mgThickener / texture agentFunctional
Potassium Sorbate40 mgPreservativeFunctional
Natural Flavor100 mgFlavourFunctional
Water (to 40 g)2.84 gCarrier / activity waterFunctional
Serving size: 40 g · Carbs: 30 g · Sodium: ~200 mg · pH: 3.8–4.2Est. $0.24/serving

Why Each Ingredient?

Every ingredient has a documented function. Nothing is added for label appeal.

Maltodextrin DE 10-15

16.7 gHigh evidence

Maltodextrin is a glucose polymer — chains of glucose units linked together. In the gut, it hydrolyses rapidly to free glucose, which is absorbed via the SGLT-1 sodium-glucose co-transporter. DE 10-15 (dextrose equivalence of 10-15) gives a relatively neutral flavour profile and manageable viscosity compared to lower-DE starches. It provides the majority of carbohydrate energy in the gel and forms the backbone of the fueling strategy.

Fructose

13.3 gHigh evidence

Crystalline fructose activates the GLUT-5 intestinal transporter — an entirely separate absorption pathway to glucose. Once SGLT-1 is saturated at ~60 g/h glucose equivalent, only fructose can increase total carbohydrate absorption. At 13.3 g alongside 16.7 g maltodextrin, the glucose-to-fructose ratio is approximately 1:0.8. This ratio has the strongest meta-analytic support for maximising oxidation rates approaching 120 g/h in trained athletes.

Sodium Citrate Dihydrate

0.45 gModerate evidence

Contributes approximately 100 mg sodium per serving. Sodium citrate is the milder-tasting sodium source: at these concentrations, sodium chloride alone can leave a sharp, salty taste. Citrate also acts as a mild alkalising buffer, partially counteracting the acid load from citric acid and helping to stabilise the flavour profile of the final gel. Combined with sodium chloride, it achieves ~200 mg total sodium — within the 150–250 mg/serving target range.

Sodium Chloride

0.24 gHigh evidence

Table salt. Contributes ~100 mg sodium and the chloride anion lost in sweat alongside sodium. The body loses approximately 20–80 mmol/L sodium in sweat depending on individual variation and acclimatisation status. A 200 mg sodium dose per gel replaces a meaningful fraction of sweat losses when gels are taken at 2–3/hour, without over-supplementing athletes with lower sweat rates.

Potassium Chloride

0.10 gModerate evidence

Contributes ~50 mg potassium. Potassium is the primary intracellular electrolyte and is lost in sweat at approximately 150–500 mg/L. Acute potassium depletion sufficient to cause cramping or performance loss during single-session exercise is unlikely in healthy athletes, but inclusion at low doses aligns with multi-electrolyte replacement philosophy and adds negligible cost or complexity.

Citric Acid

0.15 gFunctional

Drops the pH of the finished gel to approximately 3.8–4.2 — below the 4.6 threshold for acidified food classification. At this pH, most spoilage organisms and pathogens cannot grow, significantly extending shelf stability without refrigeration. Citric acid also contributes tartness that balances the sweetness of fructose and maltodextrin, improving palatability and reducing the perception of cloying sweetness during intense exercise.

Xanthan Gum

0.08 gFunctional

At 0.08 g per 40 g serving (0.2% w/w), xanthan gum creates the characteristic viscous, spoonable-to-pumpable gel texture. It is a GRAS (Generally Recognised as Safe) polysaccharide produced by fermentation. Critically, xanthan provides pseudoplastic behaviour: it thins under shear (when squeezed from a sachet), making the gel easy to consume, while thickening at rest, preventing the gel from being too watery. Temperature affects viscosity — the gel becomes thinner above 25°C.

Potassium Sorbate

0.04 gFunctional

A GRAS preservative effective against yeast and mould at ≤0.1% use level. Its activity is pH-dependent: below pH 4.6, the undissociated sorbic acid form predominates, which is the antimicrobially active species. This is why citric acid and potassium sorbate work synergistically in this formula. Without the acidic environment, sorbate at this dose would be largely ineffective. Note: homemade batches should be consumed within 2–4 weeks without validated commercial shelf-life testing.

Indicative Ingredient Costs

Bulk pricing based on standard 25 kg food-grade orders. Prices vary by supplier and region.

IngredientPer ServingPrice/kg (est.)Grade
Maltodextrin DE 10-1516.70 g$3.10/kgFood Grade / FCC
Fructose13.30 g$4.20/kgFood Grade / FCC
Sodium Citrate Dihydrate450 mg$6.50/kgFood Grade / FCC
Sodium Chloride240 mg$0.64/kgFood Grade / FCC
Potassium Chloride100 mg$5.02/kgFood Grade / FCC
Citric Acid150 mg$4.83/kgFood Grade / FCC
Xanthan Gum80 mg$14.00/kgFood Grade / FCC
Potassium Sorbate40 mg$12.05/kgFood Grade / FCC
Natural Flavor100 mg$30.00/kgFood Grade / FCC
Total per serving40 g~$0.24vs ~$3.50 retail

Prices are indicative and sourced from bulk ingredient distributors (Bulk Supplements, Parchem, Kerry Group distributors). See Ingredient Sources for verified supplier links.

Formulation Notes

Texture & Viscosity

Target viscosity is approximately 8,000–15,000 cP at rest — pumpable under finger pressure but not watery. Xanthan gum at 0.2% achieves this range at room temperature. Above 30°C, the gel becomes noticeably thinner. Adding a second xanthan pass (hydrating in cold water before blending into the syrup) improves hydration and final texture consistency.

Osmolality Considerations

This gel is hypertonic by design (~1,200 mOsm/kg undiluted). Never instruct athletes to consume gels without water. 150 mL water alongside a 40 g gel dilutes to approximately 350–400 mOsm/kg in the stomach. 250 mL achieves near-isotonic conditions (~290 mOsm/kg) supporting maximal gastric emptying rate. Do not mix gels with sports drinks — the combined carbohydrate load and osmolality can impair absorption.

GI Tolerance

Fructose at 13.3 g/serving may cause GI distress in athletes with fructose malabsorption (estimated prevalence: 30–40% of the population at some level). Symptoms include bloating, cramping, and loose stools. “Gut training” — practising high-carbohydrate intake during training sessions — demonstrably increases intestinal GLUT-5 expression and fructose absorption capacity over 4–8 weeks. Always test new formulas in training, never on race day.

Sodium & Sweat Rates

200 mg sodium per gel is a reasonable mid-range target. Individual sweat sodium concentration varies from ~230 mg/L to over 1,150 mg/L (a fivefold range). At 60–90 g/h fueling (2–3 gels/h), this formula delivers 400–600 mg sodium/h — adequate for average sweaters in moderate conditions. Heavy sweaters in heat (>1.5 L/h sweat rate) should supplement with a separate electrolyte product or pair this gel with the Hydration-500 mix.

Important Disclaimer

This formula is provided for educational and research purposes only. It has not been evaluated by the FDA or any regulatory authority. Always consult a registered dietitian or sports nutritionist before using any homemade supplement. OpenFuel formulas are intended as educational references for athletes and coaches interested in sports nutrition science. Homemade food products carry inherent safety risks including contamination, measurement error, and inadequate preservation. Competitive athletes should verify all ingredients against the current WADA Prohibited List and consult a WADA-accredited laboratory if anti-doping compliance is required. This is not medical or dietary advice.