Turning a Concept into a Product

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Turning a Concept into a Product
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OBJECTIVES

• TO DETERMINE HOW THE CONCEPT CAN TO TURNED INTO A
  PRODUT
• TO OBTAIN AN INITIAL PRODUCT FOR EVALUATION
• TO UNDERSTAND ALL FACTORS AFFECTING PRODUCT
  ATTRIBUTES
• TO SCREEN INGREDIENTS AND FORMULATIONS
• TO ASSESS PROCESSING REQUIREMENTS
• TO ASSESS PACKAGING AND STORAGE NEEDS

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Steps in the Process

• Protocept
• Prototype
• Final Product

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PROTOCEPT DEFINITION

• A PROTOCEPT IS THE PRODUCT DEVELOPED IN THE
  LABORATORY TO MEET THE PROMISES OF THE PRODUCT
  CONCEPT
• PROTOCEPT DEVELOPMENT DEVELOPED THROUGH
  INTERATION UNTIL READY FOR PROTOTYPE DEVELOPMENT
• PROTOCEPTS MAY NOT BE TECHNICALLY FEASIBLE

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Prototype Definition

• Prototypes are technically feasible
• A Prototype is The Outcome of a Protocept,
  Generally Optimized Through Pilot Plant Trials
• Generally Utilizes Appropriate Statistical
  Designs for Optimization at the Pilot Plant Scale

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Final Product Ready to Launch

• Step After Prototype that includes
• Scale Up
• Factory Trials
• Attributes Finalized
• Regulatory Requirements Met
• Shelf Life Determined
• Market Strategy Developed
• Distribution Channel Established

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PROTOCEPT DEVELOPMENT

• Interpretation of the Concept
• Product Attributes
• Formulation Ingredient Selection
• Processing Steps and Conditions Established
• Specifications
• Product Assessment
• Packaging
• HACCP
• Shelf Life Evaluation
• Pricing
• Consideration Of Regulation Compliance

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QFD -QUALITY FUNCTION DEVELOPMENT

• What do Customers Want
• How to Measure Wants
• Target Values Required
• Competitive Standing Desired
• Short Term/long Term Strategies
• Ingredient/process/packaging Relationships to
  Product Quality

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PROCESS - PRESERVATION STRATEGY

• FRESH
• FROZEN
• DRIED
• INTERMEDIATE MOISTURE
• PASTEURIZED/REFRIGERATED
• STERILIZED/CANNED
• CONTROL OF OXIDATION/FLAVOR STABILTY

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PRODUCT ASSESSMENT

• EVALUATION OF QUALITY ATTRIBUTES
• SAFETY ASSESSMENT
• SHELF-LIFE ASSESSMENT
• REGULATION COMPLIANCE
• DETERMINATION OF ACCEPTABLE VARIANCE - CONTROL
  LIMITS

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PRODUCT ATTRIBUTES REQUIRED?

• MARKET TARGET -
• PHYSICAL --COLOR, TEXTURE, FORM, ETC.
• FLAVOR
• SAFETY
• CONVENIENCE
• ETC.
• SHELF-LIFE DESIRED
• PACKAGE REQUIREMENT

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PRODUCT ATTRIBUTES

• HOW TO ACHIEVE ATTRIBUTES?
• HOW TO MEASURE ACHIEVMENT?
• ROLE OF SPECIFICATIONS FOR INGREDIENTS, PROCESS,
  PACKINGS, SHELFLIFE
• IDENTIFY INTER-RELATIONSHIPS AFFECTING ATTRIBUTES

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HOW WILL ASSESSMENT BE DONE?

• WHAT METHODS WILL BE USED TO EVALUATE THE
  PRODUCT?
• ATTRIBUTES?
• SAFETY?
• SHELF LIFE?

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FORMULATION

• THE HEART OF ANY NEW PRODUCT IS IN ITS
  INGREDIENT COMPOSITION
• INITIAL SCREENING AND FEASIBILITY TESTING
  REQUIRED
• SELECT A STARTING RECIPE
• TRANSFER TO A PRODUCT FORMULA
• WHAT ARE THE CRITERIA TO BE USED?
• TEST COMPATIBILITY WITH PROCESS

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ASSESSMENT

• ARE NEW METHODS NEEDED?
• WHAT IS THE SIMPLEST APPROACH?

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PLANNING THE DEVELOPMENT PROCESS

• THERE ARE TWO GENERAL APPROACHES
• ONE VARIABLE AT A TIME
• PLANNED EXPERIMENTAL DESIGN
• OF THESE TWO, CAREFULLY DESIGNED EXPERIMENTS ARE
  THE BEST APPROACH
• INTERACTIONS OF INGREDENTS NOT PREDICTABLE
• INGREDIENTS CAN DICTATE PROCESS
• PROCESS CAN ALTER INGREDIENTS AND INGREDIENT
  INTERACTIONS

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INGREDIENTS

• IN ALMOST ALL FORMULATED FOODS, EVERY INGREDIENT
  WILL HAVE AN INFLUENCE ON BOTH THE PROCESSING
  REQUIREMENTS AND ON THE FINAL CHARACTERISTICS OF
  THE FINISHED PRODUCT
• NEED TO UNDERSTAND INGREDIENT INTERACTIONS
• INTERACTIONS OFTEN ARE NOT PREDICTABLE

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Example of Unexpected Ingredient Interaction on
Viscosity
   
   
   
Polysach- aride. Alone protein 2mM salt protein salt
A 200 85 90 35
B 157 145 135 140
C 167 150 140 105
 
 
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INGREDIENTS

• SELECTED TO PERFORM A SPECIFIC FUNCTION - WHAT IS
  NEEDED?
• QUALITY APPROPRIATE TO PRODUCT
• MEET PERFORMANCE SPECIFICATIONS
• MEET SAFETY SPECIFICATIONS
• LEAST COST FUNCTIONALITY
• PROCESS ABILITY
• AVAILABILITY - CONSIDER JUST IN TIME

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INGREDIENTS -MULTIPLE FUNCTIONALITY

• SOME INGREDIENTS HAVE MORE THAN ONE FUNCTION IN A
  FOOD
• THE SAME INGREDIENT MAY PROVIDE A DIFFERENT
  FUNCTIONALITY AT DIFFERENT STEPS IN THE PROCESS
• INTERACTIONS CAN CHANGE THE FUNCTIONALITY OF AN
  INGREDIENT
• PROCESSING CAN ALTER INGREDIENT FUNCTIONALITY

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FOR YOUR PRODUCT -

• WHAT FUNCTIONS DO YOU NEED?
• WHICH INGREDIENTS GIVE THESE FUNCTIONS?
• WHICH ARE THE CRITICAL INGREDIENTS?
• HOW MUCH OF EACH INGREDIENT IN NEEDED? HOW WILL
  KNOW?
• ARE INTERACTIONS KNOWN?
• ARE PROCESS/INGREDIENT RELATIONSHIPS WELL
  UNDERSTOOD

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WWHICH INGREDIENTS

• CAN AFFECT SAFETY?
• CAN AFFECT PROCESSING CONDITIONS?
• CAN BY AFFECTED BY PROCESSING CONDITIONS?
• INFLUENCE SHELF-LIFE?
• INFLUENCE SENSORY PROPERTIES?

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IN SELECTING INGREDEINTS - CONSIDER

• WHAT IS YOUR PRODUCT?
• FOAM, EMULSION, GEL, ETC?
• REQUIRED PRODUCT FUNCTIONALITY?
• HOW WILL PRODUCT BE
• PROCESSED
• PACKAGED
• DISTRIBUTED

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IN SELECTION PROCESS - CONSIDER

• Equipment
• Times
• Temperatures
• Pressure
• pH
• Rheological considerations (shear, etc)
• Order of Addition

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Concept to Prototype is

• A STEP-WISE PROCESS
• CONSIDERS ALL COMPONENTS THAT INFLUENCE THE
  CHARACTERISTICS OF THE END PRODUCT
• UTILIZES GOOD EXPERIMENTAL DESIGN
• RECOGNIZES BOTH MARKET AND TECHNOGICAL ASPECTS OF
  DEVELOPMENT