Product Development
- We facilitate the exploration of new and innovative food concepts such as finished ready mealsor meal kits, nutrition bars, dehydrated snacks, soups, sauces and condiments.
- Next step is to profile the delivery model, whether it will be a fresh, frozen, or shelf stable product.
- Finally, we determine whether the client has their own plant, requires design-build or producing via a co-packer.
- Identifying quality standards such as eye appeal, taste, aroma and texture.
- We can confirm sensory attributes, we develop a strategy for transitioning from the ideation stage to marketability.
- We can also commercialize an already successful product at the “mom & pop” level, executing the transition to large scale production.
- Researching function ingredients based on clean label requirements and consumer preference.
- Define functional ingredients required to maintain flavor profiles and bring the product to scale.
- Preparing bench sample products that meet or exceed the gold standard.
- Providing standard nutrition and ingredient declarations in compliance with FDA and USDA regulations.
- Adjusting formulations when necessary to meet certain nutrition values or claims without jeopardizing a gold standard.
- Delivery model to the consumer and identify visual aesthetics, packaging materials, shelf life and machinery to bring the product to market.
- Identifying process flow, specialized equipment sized to bring the product to scale without jeopardizing taste, quality, cost and safety.
- Articulate systematic methods that incorporate use of large scale equipment, time and core temperature check points and other process controls.
- Facilitating taste panels.
- Developing sales presentations in person, on-line and in the field.
Culinary Operations
- Margin Analysis: This is an operations tool used to determine product viability. How? We utilize finished formulas and economize the cost to produce by optimizing the ratio of food cost per unit, packaging and end to end labor. Marketing, warehousing and transportation are then factored in. Once the estimated overhead has been calculated, a gross profit model is established. In the case of retail distribution, we create a formula that illustrates what it takes in order to move your product to national distribution.
- Ingredient Sourcing: We will determine the best way to purchase specific ingredients, direct from the manufacturer, brokerage representation or through a local distributor.
- Vendor Price Negotiations and Minimums: There are instances where the operator does not have the facility or resources to carry massive amounts of inventory and in doing so is left in the hands of a local distributor. Our service allows you to leverage purchasing power in order to capture maximum savings per category. Without such programs in place, operators subject themselves to unnecessary markups and price swings.
- Co-packing Relationships, RFQ *(Request for Qualification) and RFP *(Request for Pricing): We will take the lead and helping the operator to establish relationships with co-packers, prime vendor purchasing programs by category, chemical and cleaning services, laundry services and equipment purchases.
- Recipe Software Implementation: Once vendors are established, we work with operators to accurately manage cost variances, inventory and distribution. Then, assist in finding the right software tools to economize the purchasing function, perform initial data entry and articulation of ingredients, sub-recipes and master formulas.
- Production Scaling and Product Launch: Once the right tools are in place, we establish a “prepare to produce” protocol to allow for proper production scaling, specification compliance, shopping lists, purchase orders, pre-production review of processing methods, hands-on launch on the production floor, along with confirmation of yields and cost.
Plant Design
Technical Advisory
One of the most important strategic decisions for food companies is whether to enlist the services of a co-packer, who can handle the production leg work OR to build your own facility. The basic rule is this: The more specialized, proprietary and cost sensitive the product and process, the more it makes sense to build your own.
Services offered:
- Working hand in hand with architects, mechanical and structural engineers to determine a safe and efficient flow that works within the confines of an existing building or in some cases new construction.
- Sketching schematics and provide DWG files as needed, based on space requirements for various phases of production to include receiving, storage, pre-prep processing, hot production, cold chain, assembly-packaging, shipping, administrative and employee areas.
- Specify and source equipment applications designed to optimize the transition from homestyle prototype or restaurant style preparation to commercialized high volume production in a manufacturing setting.
Food Safety
Hazard Analysis Critical Control Point (HACCP). The ability to write a comprehensive food safety plan stems from familiarity with the product line and knowledge of any risks associated with the production process. Why? Because in many cases we helped you create it in the first place. And if we were fortunate enough to assist in the design of your facility, knowledge of all of nooks and crannies is another plus because we know what to look for. That’s what a HACCP food safety management system is all about; knowing the hazards specific to the operation and managing them in a way that is practical, yet gets the job done.
Here are the services we offer for writing your HACCP plan:
- Written in compliance with USDA and FDA regulations.
- Articulate GMP (Good Manufacturing Practices) to the type of product and size of operation.
- Establish SSOPs (Sanitation Standard Operational Procedures) that are practical.
- Perform a risk assessment to identify hazards coupled with simple solutions.
- Organize training of personnel.
- Oversee shelf life studies to determine reliable best-buy dates. (Good for direct-to- consumer and retail product lines.)
- Facilitate third party audits once your product and program are well established.
Experience
Testimonials
I am pleased to take this opportunity and express my appreciation for the comprehensive update of ingredient specifications as part of a continuing effort to improve management systems for Corporate Food Operations. The scope of your work required constant follow-up with buyers in the RCCL Hotel Purchasing Department. Feedback indicates that your performance was well received and has helped to position us on the right track.
Rudi Sodamin Director
Corporate Food Operations