Barb Stuckey y & Candice e Lin, Mattso son Intr trodu - - PowerPoint PPT Presentation
Barb Stuckey y & Candice e Lin, Mattso son Intr trodu oductions: ctions: Barb Stuckey Candice Lin Mattson Par art t I: Bas asics ics of HPP P Produ oduct ct Develop elopme ment Par art t II: : Th The e Logisti istics
Barb Stuckey y & Candice e Lin, Mattso son
Intr trodu
ctions: Barb Stuckey Candice Lin Mattson Par art t I: Bas asics ics of HPP P Produ
ct Develop elopme ment Par art t II: : Th The e Logisti istics cs of HPP Deve velopm
ent Par art t III: I: A co compa parative rative sam ampli pling Q&A
7
A A GRE REAT AT PRO RODUCT DUCT IS S YOUR UR UL ULTIMATE TIMATE COMP MPETITIV ETITIVE AD ADVA VANTA NTAGE GE
We devel velop
ucts ts fo for eve very y category tegory, , consu nsume mer need d state te, , technol hnology, , tempera mperature ure state, ate, culinary inary trad adition ition, , and d channe nnel of f dist istribution. ribution.
9 Mattson Facility in Northern CA Mattson Facility in Northern CA
Test Concepts with Consumers Learn From Consumers Identity Design Brand Development Package Design & Development Ideate & Explore Commercialization Scale-Up Identify an Opportunity Develop Theoretical Concepts Launch Product Design & Development
14
SINCE 1977, MATTSON HAS BEEN THE SILENT PARTNER BEHIND SOME OF THE MOST INNOVATIVE BRANDS IN THE MARKET
Juices
Deli Meats + Cheese
Introduc ucti tions ns: Barb Stuckey Candice Lin Mattson Part I: Basics of HPP Produc uct Devel velopme ment nt Part II: The Logisti tics of HPP Deve velopment ent Part III: : A compa mparative sampl mpling
17
Seeking a new platform for growth
Scale-up and Commercialization Kick-Off & Briefing & Draft Plan Select Path Forward & Initial Co- Packer Search Co-Packer Visit Protocept Refinement R2 Protocept Refinement R3, 5 SKUs Consumer Testing / Groups Protocept Refinement R4 Scale-Up / Plant Testing Support Start
Final Information Transfer for Launch Protocept Development of 2-3 SKUs Processing Technology Assessment
02 01 03 04 05 06 07 08 09 10 11
Technology Exploration & Assessment Product Development & Copack/Go-to-Market Search Pasteurize Hot Fill HPP Aseptic
What HPP Does Not
What HPP Does
What HPP Does Not
BASICS OF DEVELOPMENT FLAVOR TEXTURE COLOR SHELF LIFE FOOD SAFETY
Clean label price brand nutrition
28
Demanding Consumers They’re food-savvy They demand bold, complex flavors HPP enables flavor explosions!
pasta, veg Al dente pasta Al dente veg Even chunks of cheese!
processes are sub-par versus HPP Fresh tomatoes, carrots, etc. Fresh herbs Side-by-side sampling at end!
Texture re Concern rns
Vegetables, i.e. onions can become translucent odd maybe not right process
31
Yes, you could do aseptic gazpacho, but not in green flavors like Gazpacho Verde or Beet
Green colors more vivid Probably due to the cell disruption under high pressure Release of chlorophyll into the matrix
34
Formulate with “natural colors” that will survive HPP, but could wash out, or brown under thermal process conditions. Bolder and more vivid colors in vegetables and fruit products Guava, banana, and avocado Puree all have similar color (and flavor) as fresh puree after HPP Guacamole retains fresh color for up to 45 days processed through HPP versus non HPP
2 Lôpez-Malo, et al., 1999; Palou et al
Red (i.e. berry) jams have superior color from HPP vs. heat treatment Both L values (Brightness) & a-value(redness) are improved for HPP
1 Non-Thermal Processing Effects on Fruits and Vegetables Phytonutrients, Fauzi, Sulaiman, et al
Leve verage age HPP to crea eate te better tter-for for-you you foods
with th longer nger shelf elf life. fe.
Increase shelf life of deli salads
10
14
Deli meats increase shelf life to
reduce additives of sodium diacetates and lactates Refrigerated yogurt beverages
life by eliminating spoilage microorganisms while it retains the probiotic organisms Great for non
1 Lôpez-Malo, et al., 1999; Palou et al 2 Ohio State University Extension , 2011
Probiotic Bacterial Spores like Bacillus coagulans Ganeden BC30 resist High Pressure High Pressure above 440 [Mpa] reduces the spoilage microorganisms thus extending shelf life while maintaining the starter culture For health For label claims Non treated cold filled yogurt beverage showed unacceptable levels of yeast and mold after 28 days, while HPP treated products remained acceptable up to 90
Again, great for companies that don’t have dairy-type DSD
38 1 United States Patent 7,854,950, B2, Carrol, et al. Dec 21, 2010
Introductions: Barb Stuckey Candice Lin Mattson Part I: Basics of HPP Product Development Part II: The Logistics of HPP Development Part III: A comparative sampling
39
40
2 PI PILOT OT PLANTS TS 10,000 00 SQUARE UARE FEET OF DEVELOPME LOPMENT NT SPACE CE 30 MEMBE BERS RS OF CULINAR INARY, , R&D, , SCALE LE-UP UP TEAM REGULA LATORY TORY INPUT UTS, S, COPACK ACK SEARCH RCH & COMMERCI MERCIAL ALIZAIT ZAITON ON
Choose suppliers with documented processes in place! Good Agricultural Practices (GAPs) Good Manufacturing Practices (GMPs) If initial micro load of unprocessed product high: No guarantees post-HPP load will be acceptable Could result in shorter shelf life
Early package decision critical Do this at beginning of project! All must withstand water and pressure Packages Tamper evident seals Closures Labels Even during benchtop development, test in chosen package
Underst rstand your raw materia ials! ls!
Safe fety ty Initial micro-load Quality, i.e. “juice grade” Most suppliers assume there will be kill step Understand inherent micro food safety risks and target organisms I.e. root vegetables C. botulinum risk
Understand your raw materials!
Sensory Key attributes may be muted or amplified by HPP processing Test on benchtop, then HPP, then re-adjust Example: Sour ingredients can get more sour Bitter get more bitter Spices/heat can bloom Garlic: unpredictable Herbs need to be adjusted But don’t trust us: you have to do the development and testing!
Formul mulation is Key! y!
And warn clients of risk
Don’t do too many rounds of development before running through HPP Partner with HPP co-packer or research facility early for small scale testing Challenges: Off notes Viscosity Marrying of flavors
46
Consider regulatory implication of ingredients Processed ingredients = finished product cannot be considered fresh Frozen puree = NOT fresh Frozen lemon juice = NOT fresh Can say, “Made with fresh apples” Or, get clever with labeling
Consider enzymatic activity of raw materials Will enzymes be deactivated by HPP? If not, pre-processing step required: Blanching/other Heating Acidifying Enzymatic inhibitors
Harness the cumulative effect of multiple food safety hurdles! Low acid + HPP + refrigeration
Establish baseline microbiological load Identify key target spoilage and pathogenic microbes during development
Not perfect but, an early indicator of shelf life after scale up Validate benchtop study with plant-produced product
50
Safety
HPP effective at reducing non
bacterial populations Does not inactivate bacterial spores like
botulinum. Validation Challenge Study: with known pathogen of
51
Good Manufacturing Practices (GMPs) Hazard Analysis Critical Control Point (HACCP) Recall Capabilities Food Defense Plans Distributor Cold Chain Management Quality standards for accepting or rejecting shipments of raw materials Monitoring programs tracking raw material inherent seasonal variation
Schedule multiple full scale process tests at the co-packer to achieve batch to batch consistency Validate critical control points identified in benchtop development
52
Introduc ucti tions ns: Barb Stuckey Candice Lin Mattson Part I: Driver vers of HPP Produc uct Devel velopme ment nt Part II: The Logisti tics of HPP Deve velopment ent Part III: : A compa mparative sampl mpling
53
100% Plant Based Drink Chilled or Hot
100% % Plant Based Salsa overtook ketchup as America’s number 1 condiment in 2013
55