The problems faced by companies trying to reduce levels of salt in food have been laid bare in a government report that reveals many are set to spectacularly miss their targets this year.

Documents from nearly 150 companies signed up to the Department of Health’s Responsibility Deal have revealed a raft of suppliers, including United Biscuits, General Mills and Kraft, are falling way behind pledged reductions.

Although some are on course, others are beset by technical issues around preservation and taste, involving meat, bread, cheese, cereals, cakes and sauces.

United Biscuits has hit none of its 2012 targets to date and expects to reach just 25% by the end of the year. In the report, it warned of “significant technical challenges associated with ensuring the taste and quality of the products are not compromised”.

General Mills, which is on course to hit 30%, warned cutting salt levels had proved “particularly challenging” in cereal-based products including bread, cake and pastries.

Kraft, which is set to miss more than half its targets, said changes involving several biscuit and cheese lines would “not be feasible” without compromising taste.

Some companies are now planning to scrap SKUs that are not worth the investment in reformulation. Premier Foods, which has committed to cut 286 tonnes of salt by the end of 2012, said two SKUs would be delisted by the end of the year because it could not meet the target. PepsiCo said it would delist at least one SKU in January 2013.

Nestlé warned of an uneven playing field in Europe. “If imported competitor products remain at higher salt levels, we believe that due to taste preference, consumers will opt for these,” it said in the report.

Last year, boffins at Leatherhead Food Research were hired by the FDF and the BRC to look for a scientific breakthrough to help companies meet salt pledges.

FDF director of food science and safety Barbara Gallani, said there was “no magic formula” and warned that even if scientists did discover a breakthrough it would take months to implement changes. A DH spokeswoman said it would “drive forward further reductions”.

The fight to reduce salt

May 2003: Scientists find strongest evidence to date linking high salt intake and high blood pressure

March 2006: First set of salt targets published by the Food Standards Agency and the Department of Health, covering 85 categories of processed food, including bread, Bacon, breakfast cereals and cheese

March 2011: Andrew Lansley’s Responsibility Deal is launched. It includes a collective pledge by the industry to slash salt levels

February 2012: Partners pledge to deliver “a further 15% reduction on 2010 targets, amounting to a total salt reduction of nearly 1g per person per day compared with 2007 levels in food”

June 2012: DH figures show average salt intake at 8.1g per day, against the recommended 6g, despite consistent reductions

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