PROJECT EXAMPLES
Seaweed Processing
Started up new fresh frozen seaweed process in Alaska and commercialized with SQF, Organic and relevant certifications. Designed and installed custom processing and equipment. Tripled production and obtained 50% cost reduction for dehydrated seaweed to fulfill ingredients destined for CPG products. Developed seaweed-based snack foods and CPG products, seasonings and nutraceuticals. We can provide turnkey service on seaweed processing system to create stabilized products (frozen or dehydrated).
Snacks and Salad Dressing
Developed process for vegetable snack chips and fruit snacks. Provided product formulation, ingredient selection and processing techniques for shelf stable and refrigerated salad dressings.
Bar Product development and Manufacturing
Developed formulas and concepts on bars to showcase ingredient or functionality. We qualified new manufacturers for major bar manufacturer and ran start up trials followed by commercialization. Developed statistical analysis of the process as an online tool for decision making.
Provide Nutraceutical product development strategy
Delivered strategy development for vegetable/spice product encompassing front end literature search, techniques of development, technical hurdles, product and process identification.
Future technologies for liquid and snack food processing for large snack company
Identified and prioritized new thermal and non-thermal processes for snacks and liquids/pastes/sauces for better nutritional value and higher product quality. Connected with worldwide manufacturers and research institutions to develop and deliver a feasibility plan with prioritized technologies of focus.
Process improvement and cost savings for Leading produce and Berries Manufacturer
Devised cutting/chopping techniques to reduce cellular leaf damage of product. Implemented Best Practices for maximum surface water removal from washed salad greens and minimizing cellular damage in leaves for extended shelf life. Automated Vacuum Cooling process to deliver consistency and 30% energy savings for > 1 billion annual pounds of fresh produce. Conducted pilot program on fresh berries quality tracking from harvest to delivery (farm to fork). Conducted research and made cold chain improvement recommendations for shelf life increase of > $100 million fresh berry business.
Aseptic Beverage Production optimization
Impacting >$700 million business, we created a system of standardizing manufacturing aseptic beverage process across multiple manufacturing facilities. Additionally we qualified new manufacturer capabilities and commissioned them from start up to full scale production. We addressed quality by improving stability and shelf life of high protein dairy beverages. Developed rapid screening methods for dairy ingredient qualification.
Plant OPtimization for Vegetable Dehydration
Audited commercial dryer settings, designed and corrected for air flow, and provide optimized settings for 30% drying rate improvement for vegetable and spice drying.
New Process development for retail smoothie product
Evaluated concept of organic fruit and vegetable smoothie kit for packaging and national frozen chain distribution. Recommended process and conducted audit of manufacturing plant.
New Pasteurization Technology
Evaluated cutting edge thermal and non thermal pasteurization process for dehydrated ingredients, spices, juices, frozen foods, RTE foods, fresh fruits and produce for large Snack and CPG product manufacturer.
Eliminating Pathogens in Frozen Food Factory
Initially we isolated the source of the pathogens. Then we moved forward with a clean and effective removal of the pathogen source. Alongside that we ungraded the equipment at the plant. We made process recommendations and modified GMPs to prevent future occurrence.modified also recommended some new processes to make sure the pathogens do not cause a problem again. We Isolated the source, provided effective removal technique, upgraded plant equipment and modified GMPs to prevent future occurrence.
Implementing New Quality Protocols for Leading salad Manufacturer
Developed IP for improved sanitation process for fresh cut and tender leaf salads. Implemented sanitizer control systems in multiple wash steps - leading to > $20 million Capital installations for enhanced wash process. Results in a fixed time wash process with predictable micro reduction.
Specification optimization for frozen Fruits and Vegetables for large manufacturer.
Created value based product personification process for purchase specs. and finished product specs. Conducted detailed review of existing product specifications to highlight key quality and value criteria for each frozen fruit, vegetable and blend product. Consolidated multiple specifications for sku reduction. Delivered simplified and impactful specifications.
Sensory Training
Developed flavor characterization lexicons, score sheets, preferential and differential sensory comparison systems for fruit and spice products. Provided expert sensory training and helped establish in-house expert classification for garlic and other spices and fruits like strawberries.