In recent years consumers' concern about food safety and health is becoming crucial. The development of healthier products seems to be a promise challenge, since functional foods are identified as one of the central pillars for the future progress of the food industry internationally. Artificial Intelligence techniques such as Knowledge Engineering, Rule Based reasoning and Expert systems are presented here as a way of technological innovation towards a knowledge-based and sustainable manufacturing in food sector. We show how these techniques are applied in a case study to support companies in the formulation of new chocolate products that reduce the impact on health status, reducing selected risk factors associated with obesity and coronary disease (fat, sugar).