FULL SCALE PRODUCTION
Streamlining the Scale-Up Process
Scaling a formulation from a small batch in a test kitchen to full production in a manufacturing facility involves adjustments that can impact taste, texture, and quality. We provide expert guidance on refining the recipe and processes to ensure the end product maintains its desired characteristics.
Our team conducts a thorough analysis of the original formulation, identifying potential pitfalls in ingredient behavior or processing methods when scaled up. We help tweak the recipe as needed, ensuring consistency and consumer satisfaction.
Comprehensive Plant Trial Support
Plant trials are a critical step before launching full-scale production. We coordinate and oversee these trials, collaborating closely with your production team to test and refine the manufacturing process.
We work alongside your staff to evaluate and troubleshoot any issues that arise during trials, such as equipment compatibility, process efficiency, or ingredient sourcing challenges. This ensures a smooth transition to full-scale runs with minimal disruptions.
Equipment and Process Optimization
Transitioning to full-scale production may require adjustments to existing equipment or even new machinery. We assess your current capabilities and provide tailored recommendations for process adjustments or equipment upgrades that will best suit the needs of your new product.
Our support includes creating custom process parameters, such as mixing times, baking temperatures, and cooling procedures, that are specific to your formulation and production line, ensuring optimal results.
Quality Assurance and Consistency
One of the biggest challenges in scaling up production is maintaining the quality and consistency of the product. We implement rigorous quality checks and set up standard operating procedures (SOPs) to ensure that every batch meets the highest standards.
We also assist in setting up a robust quality control system, including sampling protocols and testing procedures that help detect any deviations early in the process.
Efficient Production Planning and Cost Management
Scaling up isn’t just about technical adjustments; it’s also about efficient production planning. We help clients create a detailed production schedule, optimizing for batch sizes, run times, and raw material procurement to minimize waste and downtime.
By analyzing cost factors at full scale, we can identify opportunities for cost savings, whether through bulk ingredient sourcing, improved process efficiencies, or reducing production losses.
Regulatory Compliance and Documentation
As you move to full-scale production, compliance becomes even more critical. We provide guidance on meeting regulatory requirements, ensuring that your packaging, labeling, and production processes comply with Canadian food safety standards and industry regulations.
Our team helps document every stage of the process, providing you with a clear, traceable record that supports regulatory audits and enhances your product’s market readiness.
Ongoing Support and Troubleshooting
Even after the initial scale-up, our support doesn’t stop. We offer ongoing consultation to address any challenges that may arise once the product is in full-scale production. This can include troubleshooting production issues, fine-tuning processes, or advising on new market trends that may require adjustments to your product line.
Why Choose Us?
With our deep industry expertise and hands-on approach, we take the stress out of scaling up your bakery products. From initial concept to final product launch, we are your trusted partner in delivering a successful transition to full-scale production, allowing you to focus on what you do best—creating great-tasting baked goods.