June 2021 Professional Development - Scaling Up Food Production

Scaling up food formulations or processes for increased demand is an exciting and challenging time for any food company. There is a tendency for teams to simplify or expedite the process, and making this mistake incorporates risk. This event explores a central process for creating and maintaining a basis for improving scale-up success.

Zoom Meeting
Tuesday, June 15th, 2021
Time: 11:30-12:45pm
Price: $15 for members and $20 for non-members

Tom Niedoborski
Sr. Manager R&D Branded Products
Mizkan America

So You Want to Scale up a Formula? Strategies and Tips for Successful Product Launches

A product/formulation developer positions him/herself for success by planning ahead and considering perspectives of other support role functions at the production site before designing a new product at an existing production location.

Setting specific guardrails is always important for what should or shouldn’t be included in a new formula. Simplification, where appropriate, is a key enabler for flawless launches and maintaining the product quality in full-scale production.

This discussion will outline key strategies for success and maybe even help your cross-functional team members at the plant like you.

Bio: Tom Niedoborski earned a Masters in Food Science from the University of Illinois and has since been an industry professional for the past 21+ years. Over that time, Tom has led formula or process development trials and/or production start-ups at over 40 different internal and external plant locations.

Tom has concept through commercialization experience in a variety of categories including:

  • Pasta sauces (Acid, Acidified and non-acidified)
  • Condiments (dressings, mayonnaise, Miracle Whip®, BBQ and other sauces)
  • Bakery Applications (tortillas, pizza crusts, flatbreads, co-extruded products, pasta)
  • Complete meals and pizza assembly (refrigerated and frozen)
  • Meat Processing (emulsions, whole muscle, formulation and sodium reduction)
  • Process technologies (thermal/non-thermal pasteurization and commercial sterilization)

Kelsey Ryan
Food Technologist

Food Product Development and Scale-up: Considerations Not to be Neglected

In school we learn the food product development cycle and its importance, including scale-up. However, when reaching the industrial scale there is at times pressure to forego some important product development and scale-up steps for a multitude of reasons.

In this presentation I will introduce the concept of food product scale-up, and will share some of my own scale-up experiences from field research settings, in-house factory production and contract manufacturing, and present lessons-learned from various scale-up adventures.

Bio:Kelsey is a Food Technologist at the United States Agency for International Development (USAID) where she is responsible for supporting food safety and quality monitoring and auditing, product specifications, supply chain quality, and food product development, manufacturing and research. Kelsey has over 10 years of experience in food and nutrition research, formulation, and product development.

Her post-doctoral research addressed severe and moderate acute malnutrition, malnutrition interventions, and food ingredients and manufacturing of ready-to-use food aid products. Previously Kelsey spent several years in the private sector focusing on product development, manufacturing, and operations. Her assignments included new food product and ingredient development, formulation, factory support, and new factory startups. Kelsey holds a B.S., M.S., and Ph.D. in Food Science.

Nihal Raval
VP Manufacturing
Plant Based Seafood

Key Operational Considerations when Scaling up for Manufacturing

Food manufacturing has become more advanced and automated in the last 10 years. A lot of the processing and packaging technology has accelerated our ability to create new alternatives for human consumption.

Majority of these innovations start in a kitchen, lab or some small pilot facility. Eventually though if the product passes stage gates and consumers show interest, then comes the arduous yet exciting process of scaling up these innovating formulations to manufacturing facilities.

Some of the key operations considerations to keep in mind when scaling up:

  • What equipment and/or technology already exists that can be used or with minor changes provide the needed technology to process/package the product?
  • Do the processing parameters, product analytical and sensory characteristics remain the same when scaling up?
  • How simplified can the process be to run / make the product. In the end no matter how automated, operators on the floor need to understand and repeat it over and over again with precision?
  • Is it batch vs continuous operation and how can it be the most efficient process possible?
  • Is there a good validation program in place that solidifies the strong collaboration required between R&D, Quality and Manufacturing?

Bio: Nihal is a transformational leader with extensive experience in operations, supply chain, technology, project, & expansion leadership roles. Develops operational excellence as differentiated capability, delivering exceptional business value and competitive advantage. Passion for excellence and history of exceptional results, guided by customer-centric approach.

Results-driven executive and skilled influence leader, having led having led multi-site, and multi-functional teams across a broad range of successful projects, programs, and strategic initiatives. Led and motivated teams comprised of more than 200 employees and with P&L responsibility exceeding $100 million. Leader of leaders, skilled in talent development and engaged with servant leadership.

Lean Six Sigma Green Belt skilled in complex problem solving with proven results in several industries. Key interactions include CEO, CFO, COO/EVP.

Articulates compelling vision for future and motivates teams to work collaboratively toward shared vision.

Section Sponsors

We use cookies to keep you logged into our site between visits and we also use Google Analytics. By continuing to use this site you consent to the use of cookies. You can view more info about this and personal data on our Privacy Policy page.