Module Introduction – D24FP3

Food Factory Operations

Today’s Agenda

09.00-10.00 Module Introduction / Team Selection- Project Allocation

10.00-11.00 MicrosCreations - Specifications

11.00-12.00 NPD

12.00-12.30 Nutrition request

12.30-13.00 A quick look at what might be expected on 17th March!!!!!!

 Module Introduction – D24FP3
Food and Factory Design
• Learning Outcomes
By the end of the module, you should have knowledge and understanding of:
• The design and hygienic operation of food factories and plant
• The legal requirements and codes of practice for the safe operation of food factories
• Factors involved in developing a new food product

You should have developed the Intellectual skills to:

• Identify the key features determining successful new product development
• Combine hygienic requirements of food production with efficient plant layout

You should have developed the Practical skills to:

• Draw factory layouts that meet safety and efficiency criteria
• Innovate and combine formulation, marketing, design skills to produce a successful
food product

You will have the opportunity to cultivate transferable/key skills to enable you to:
• Work in a group to tight deadlines and deliver a food product with a clearly defined
specification
Timetable
Assessment Criteria
 Project Allocation – D24FP3 2011

• Garden Crackers • Project T

• Gluten free Bread • Succulent Chicken
• Gelled Sauces Burgers
• Low GI Cereal bar • Naughty Pandas
• Mise en Bouche • Sunny Slice
• Cold Soups • Tomato Squares
• Pannacotta
 Forms to be completed
• FORM1: PROPOSED LIST OF INGREDIENTS

• FORM2: PLANNING FORM: PRODUCT DEVELOPMENT PLAN

• FORM3: ORDER FORM: LIST OF INGREDIENTS/EQUIPMENT

• FORM4: MY CONTRIBUTION TO THE PROJECT:INDIVIDUAL

SUMMARY

• FORM5 (UG): MARK ALLOCATION FORM

• FORM5 (PG): MARK ALLOCATION FORM

• FORM5 (PG Prod. Assessmt): MARK ALLOCATION FORM

An Introduction to Product
Development
Dr Tim Foster
 Learning Objectives
• To define concept of a ‘new’ product

• To describe the stages of a product’s lifecycle

• To identify the key stages of the product

development process

• To understand what is meant by Process &

Product flow and Product Specification
 What will this mean?
Treat as role playing : imagine you are employed in a small factory in the real world. No one to
hold your hand or spoon feed you. Very limited guidance from superiors

All about learning as you go along, applying the knowledge

you already have and using your common sense

On your own, sort out problems yourself. This can be very

frustrating, but this is what the real world is like

Organisation,
teamwork

Begin by brainstorming the problem together.

Write down all ideas. Set targets & objectives

Liaise with technical staff, e.g. Liz, Guy. They are an invaluable
source of help when it comes to equipment & materials

If you need to see academic staff - make appointment just as you would in real situation. Whole team must
attend together OR one elected representative. Imagine your academic supervisor is the MD - their time is
very valuable, time is money

Not just a case of knocking on the academic's door & saying, can I see you in 10 mins? E-
mail them, giving a selection of times/days that are convenient for you.

Sometimes you'll have to put yourself out, miss the early bus or come over to SB
especially for the appointment. Again, this is what the real world's like
Why are the right questions important?

Einstein is quoted as having said

that if he had one hour to save
the world he would spend fifty-
five minutes defining the
problem and only five minutes
finding the solution.
 D24FP3:
So what will your NPD Require?
Ideas Ingredients Process Specifications

Plan Source Make Pack Distribute

Safety
Packaging
Cleaning / Sampling Process Design
Labelling
Feedback Factory layout
Marketing
Sensory / Microbiology / Texture

Auditing

Law & Enforcement

Team Membership and Responsibility

• Production Food Hall – 2 per team 1

• Factory Design & process / Scale-up / Location / Cleaning
• Ingredient / Process / Packaging Specifications 3
• Patent landscape
• Packaging Design / Labelling Different Departments
4
• Roll-out Plans / Marketing True Team Working
• Quality Assurance
• Microtesting / Sensory / Texture 2
 What does this mean?

• We have 12 teams
• 24 people will work on Product Production
(2 per team)
• 12 Quality Assurance (1 per team)
• 12 looking at Factory Design
• 12 Looking at Marketing Issues
 Production
• 09.00-13.00 Food Hall Friday Morning
• Responsible for contact with Liz Starr
– See forms / requirement
– Tuesday 12.00 for the Friday of that week
– No form no ingredients SO PLAN
 Quality Assurance
• Seminar on Microbiological Practice 4th
Feb (09.00-10.00 – Teaching Lab) with
Christine Dodd and Wendy Fielder.
• 11th February the will be physical /
mechanical testing methodology
discussions with Dr Bettina Wolf at 11.30.
• Use the time to build methodologies, so
your team mates learn with you
 Factory Design
• Consultation – by appointment with David Russell every
Friday Morning in Liz Starr’s office 5th Feb-12th March
inclusive

• David Russell has a BSc and PhD in Materials Sciences from

Cambridge University, UK.
• He has over thirty years experience of working in the food
industry, mainly with multinationals such as Mars
Confectionery, Nabisco, and Masterfoods Petcare.
• He has recently worked for the Food Processing Knowledge
Transfer Network, identifying new technologies for application
in the food industry.
• His work has taken him into most aspects of R+ D associated
with food manufacture, especially into the successful
development and implementation of new products and
ingredients.
 Marketing Issues
• Input from Supervisor in the short meeting
you have
• Consultation with Tim Foster – by
appointment
• 11th February there will be Micros training
for one team member from each team in
the Graduate Centre.
 Assessment
Criteria Evidenced mainly by
Product Design Product report
Determine ingredient, process, product and packaging specifications. Report and Presentation
Production of Concept and Final Specification.
Students have demonstrated initiative and innovative thinking in their choice of
ingredients. Choices are justified.
Quality Assurance Report and Presentation
Identify and use microbiology and material testing protocols to assure the product
meets the brief.
Ensure microbiological stability for typical supermarket shelf-life.
Devise a material test to compare properties of burgers.
Manufacturing Capability Drawing for Food factory
Identify a location for the manufacture of your product, indicating which utilities you Design and Presentation
will require, the factory layout / construction and which unit operations will be used.
Select one area to expand upon, explaining why it is essential and what are the issues
relating to it.
Product Positioning Report and presentation
Show due diligence in identifying the patent landscape relating to your product.
Carry out packaging design and use appropriate labelling for your product.
Indicate product market position and what marketing / roll-out plans will be used.
Provide MicrosCreations Specification sheet for PackCopy authorisation.
Useful Web Resource

The Food Technology Website

http://www.foodtech.org.uk
The Food & Drink Innovation Network
http://www.fdin.co.uk/seminars/previous.html
Concept Generation and Evaluation-
Managing the NPD Funnel

FDIN 29th April 2010

Tim Nicol
©The MIH Centre Ltd,
www.mihcentre.co.uk +44/0 207 379 3340
Improve your chances
Creating and ruling block-buster
categories

FDIN, June 2010

Presented by David Jago
 And bear in mind:

Great concepts can fail for a variety of reasons

What didn’t work then might work now
Don’t overdo flavour/line extensions
New flavours should maintain consumer interest in the category,
not create additional sales via a separate brand equity!
Steal with pride
Copy and improve
Consumers seem to have a narrow tolerance for new things—you
can’t make it too much of a disconnect
The end result has to have real, tangible benefits

27 Group. All rights reserved. Confidential to Mintel.

tel International
 Turbo charging your NPD
process
3 June, 2010

prepared for: FDIN prepared by: Claire Nuttall date:3 June, 2010 issue: 01
What Makes Big Brands Stay Big?

3 June 2010
Jonathan Banks

jonathambanks@hotmail.com

Special acknowledgement and thanks to:

Craig Twyford, The Nielsen Company
5 rules that ensure the big brands stay big
1. The age at which the emotional engagement occurs

2. Beware of “creative destruction”

3. Continually evolve the brand in line with macro

trends

4. Maintain & justify a premium positioning

5. Dominate the emerging channels

September 17, 2009

80% of CEO’s believe their
brand provides a superior
customer experience

8% of their customers agree

September 17, 2009

Source: Bain & Company
 Successful products…
• Consumer demand
• Product quality –
consistency
• Distinctive
• Product safety
• Brand Trust and
Awareness
• Marketing
Dairylea changed the proposition to stay relevant

September 17, 2009 Page 34

Kellogg’s shifted emphasis

September 17, 2009 Page 35

...and redefined the tasty segment...

September 17, 2009

Lets take a look at some of
these stages
Screening and product
development…..
Screening the idea – what questions
should you ask?

• Is raw material readily available?

• Does it process easily?
• What is the shelf life?
• Any safety issues?
• Does it package easily?
• What will be the cost?
• Who will buy it?
 What investment is required for
production?

• A new product may need:

– New technology – high
investment or
– New techniques/some new
equipment – modify factory or
– Minor investment or
– May only need existing facilities
 Stages to Product
Development
• Produce Prototype
• Write Raw material, Process, Product and
Packaging specifications (e.g.’s to follow)
• Microbial and hazard checks (HACCP)
• Determine QA/QC procedures
• Storage trials
You need to produce a
• Patents? proposed process flow
• Pre-production trials for your product
showing CCPs
 Time is of the essence
• Short timelines are the norm in the food
industry
• Don’t waste time; stay focused on the
brief
• Work as a team – all members should
contribute equally.
• Delegation & Accountability is essential
 Useful References
• Earle M, Earle R & Anderson A
(2001) Food Product Development
• Fuller G W (1994) New Food Product
Development CRC Press
• Side C (2002) Food product
development based on experience.
Iowa State Press
• CIAA ETP Food For Life
• RSC The Vital Ingredient
 Useful References
• Brody & Lord, Developing new food products for a changing
marketplace, CRC.

• Earle & Earle, Case studies in food product development, CRC.

• Fuller, New food product development, CRC.

• Lopez-Gomes & Barbosa-Canovas, Food Plant Design, CRC.

• Moskowitz, Saguy & Strauss, An intergrated approach to New

Food Product Development, CRC.
 Example of Raw Material
Specification
• Oven Fried Chicken Leg - Chicken
• Chicken legs to be obtained from Chick Leg Company, Poultry
Lane, Pullet.
• Certification for Salmonella-free must accompany.
• Must be free of all tendons, cartilages, large blood vessels, blood
clots, and discolorations.
• Temperature on delivery must be 4C or below.
• Chicken must be placed in appropriate (specified) cold storage
room immediately on arrival

In addition, a Specification will be needed for

all other raw materials, e.g. for the batter
ingredients and the frying oil
 Example of Process Specification

• Oven Fried Chicken Leg

• The batter shall consist of a flour-type base with other
ingredients (specified) to produce desirable texture, flavor,
and colour (specified).
• The pick-up of batter and breading prior to frying shall be
approximately 14-16 percent of the weight of the chicken.
• Chicken should be processed in vegetable oil for at least
two minutes at 160C.
• The finished fried chicken should have an internal
temperature of 85C.
• After frying, the chicken should be immediately chilled and
quick frozen.
 Example of Product Specification

• Oven Fried Chicken Leg

• The finished product should be uniformly covered with
batter and have a uniform brown color.
• The product should be free from burnt areas.
• The edible portion of the chicken exclusive of batter, skin,
and bone must be 150g cooked weight.
 Example of Packaging Specification

• Oven Fried Chicken Leg

• Frozen chicken legs should be placed in preprinted
tetrapack (supplier), already stamped with sell by and best
before dates (specified) immediately after freezing.
• 4 legs in each box.
• Packs to be sealed (method stipulated) and placed
immediately on pallets in freezer area, ready for immediate
dispatch.
Can you think of other parameters that may
be included in the Product Spec?
• Moisture / water content
• pH
• Viscosity
• Crispiness
• Hardness
• + anything else that is an important safety
or quality parameter for that product
 Your Product Development Project
• Analyse the brief. What are the key requirements? Read the
assessment criteria carefully & make sure you stay focused
on this. There will be scientific/technical problems to
overcome. What are they?
• Decide on your approach. What do you need to do, when do
you need to do it and who will be responsible for doing it?
Write your initial time plan.
• Formulate your Microbial and Hazard checks (HACCP)
• Start developing your product
• Do (accelerated) storage trials if necessary
• Think about packaging and labelling
• Write Raw material, Process, Product and Packaging specs

BE HYGIENIC
 Wherever you are working, can you please
ensure that you:

• Thoroughly clean the work surfaces BEFORE you start work

• Wash your hands
• Wash, dry and put away all utensils after use
• Put all your ingredients together in a cupboard/on a
shelf/out of the way CLEARLY LABELLED with your name,
the date and the letters FFO clearly displayed.
• Dispose of unwanted packaging and food appropriately –
DO NOT LEAVE for someone else to dispose of
• Leave the area clean and hygienic when you leave
 Constantly EVALUATE

• How well does your product match the

brief?
• Have you planned to cover ALL
assessment criteria?
• Are there areas for further development?
• Construct a Process Flow diagram,
showing CCP’s and QC points
 Add
CCPs
to your
Process
Flow
 Basic Flowchart
A basic flowchart identifies the
starting and ending points of
a process, the sequence of
actions in the process, and
the decision or branching
points along the way.
NPD ‘Market Place’
Academic Assessment
Industry Interest (Kerry Prize)
Team Work and Enjoyment
Use of Resources
Success