A Developer's-Eye View

  On the commercial side of the business, knowing the customer is the first step toward product development. Does the customer want an assembly-line-type product in his store? Does he want to do some of the final preparation? Or, does he desire a completed product that will only need heating before it is to be served? In turn, it is a must to know the target consumer.

  After establishing a good business relationship with the foodservice vendor/customer and knowing his unique needs and wants, the developer will be able to design products that meet the needs. Unlike the institutional business, no two customers are ever alike in the commercial foodservice arena.

  The product developer has to take into consideration all the various criteria that must be met to arrive at a finished product. He or she will work with not only the foodservice customer, but often with their preferred ingredient and equipment systems, and their distribution system. The developer automatically becomes a member of a team working toward a specific goal.

  While developing the product, the scientist must consider certain criteria and procedures, including the quality and the functionality of the ingredients, and any nutritional guidelines. Appearance and sensory attributes also are critical factors, along with storage conditions and final preparation. One of the advantages of working as a team is the support of the supplier's technical staff who, in turn, become valuable consultants in the use and development of the product.

  Anyone who has ever scaled up a bench product knows that the scaling-up process isn't a one-shot process. It takes several attempts to accomplish little steps. During this time, the formula is tweaked and refined; the order of addition of the ingredients might have to be changed; and the mixing or assembling process must be finalized. It also is at this step that the equipment needs must be identified to make the desired end-product.

  As a team member, I have traveled to Europe and several U.S. locations to identify the type of equipment we needed for the final production of the product. We identified mixers, ovens and freezers. We even did some process testing at the American Institute of Baking, Manhattan, KS, using their equipment to establish our needs.

  Before a store can make and serve an acceptable product, it must have the right type of equipment. Designing a product without the knowledge of how the end-user will be preparing it is a recipe for failure. All stores don't have the same equipment; assuming they do creates all types of problems. Most foodservice operations don't have the budgets to go out and buy new equipment just for one new item. Tolerance testing of the final processed product becomes a very important development step. This should include types of equipment and their parameters (type of mixers or ovens, their actual speeds and temperatures, batch sizes, etc.).

  Packaging must allow the product integrity and quality to survive the many storage and distribution conditions encountered. Shelf-life requirements need to be considered when choosing the materials used. If the product is frozen, will it be subjected to cycling freeze/thaw conditions? What will it do to the packaging and the product it holds if this happens? What is the expected delivery time to the final destination, and what is the time frame before presentation to the final consumer?

  If the packaging is used for preparation, does it hold up to extreme temperatures in the oven or the freezer? Off-odors from the packaging during preparation also have to be considered. The packaging materials might do a good job in storage. But when used in baking or out of the freezer, do they impart any flavor transfer?

  Cost is the other critical step in choosing packaging materials. If the packaging costs more than the product, problems might result. Make sure the client's needs and budget requirements are known before making any final recommendations.

  Most commercial products are targeted for a specific market. An upscale restaurant might be looking for a base product that they can build upon with unique ingredients or one that cuts down on the skilled labor and preparation time. Pre-prepared vegetables, along with sauce mixes, fall into this category. Operators can add extra ingredients to mixes or frozen batters to make them unique. Frozen dough can be thawed and used in place of scratch recipes.

  Institutional food products require a fair amount of tolerance. Most institutional establishments want products that only require added water to prepare. Because good, competent help is difficult to find, this criteria for simplicity is even more crucial. Two other criteria for institutional foods is that they be nutritious and wholesome, since most are fed to captive audiences: children in schools, day-care centers and pre-schools, or individuals staying in nursing homes, hospitals or prisons. The products all have to withstand long holding times at temperatures that ensure food safety.
  When traveling to different regions of the country and eating in a familiar-named, fast-food operation, did the food resemble that found at the one back home? One thing chains require is consistency of appearance and quality. Mass-producing foods helps ensure the product meets these standards when it arrives at the customer's store. Making foods from scratch at individual stores often results in variable quality and consistency from operator to operator.

  With busy consumers seeking convenience and nutritional foods for their families, the foodservice industry will continue to grow and demand new and better products. It is a challenge to developers to know what is being offered and the market's new trends and needs. With that information, they will be able to design products that will take the industry into the 21st century.

Cover Story Pt - 4 - Lunchtime and Learning