Project Learning
I have been giving presentations on processing to students studying Food Technology at Cardiff Metropolitan University. These presentations are available directly to any university or college students who may be interested
Project Cost
A major chocolate manufacturer in the Dubai needed to reduce costs without in any way reducing quality. We identified improvements to their chocolate making process which reduced fat usage while retaining product quality and functionality.
Project VMS
A major American Healthcare company currently manufactures VMS products in the form of gummy jellies
In order to establish a wider range and products with unique characteristics we have investigated a very wide range of confectionery concepts in the context of using them to deliver Vitamins, Minerals and other Supplements.
The range has been narrowed down to a small number of potential concepts and potential supply partners for those concepts have been identified and investigated
Project Film
A major American healthcare company wants to extend its range of VMS products into more adult markets
I have investigated the buccal and lingual film based products including suppliers and manufacturers on their behalf and recommended potential partners
I have also prepared extensive documentation on the technologies available and the range of products from significant manufacturers
Project Oat
An established Irish company is producing an oatcake product but has serious manufacturing issues leading to high waste levels and low output efficiency
A complete review of the manufacturing process and equipment has been undertaken and a large number of developments in equipment and process have been recommended which will resolve the problems and transform the profitability of the operation
Some formulation development work has also been undertaken to allow scrap material to be recycled without affecting product quality
Project Roll
A major Gulf based manufacturer of chocolate and chocolate products wants to add a range of pan coated products to its range. I have explored competitor products, ingredients sourcing, equipment options and process development for the company. Test work and equipment specification is underway
CD New Concepts
Working with a major USA healthcare company to examine new options for some of its products within the concept of what product options might be compatible with their requirements, which might ne manufactured in house or what options might exist for third party manufacture
Project Inboard
Exploring commercial and technical options for a UK company interested in bringing manufacturing of its products (currently sourced from several suppliers) in house
Saudi Support
I work with a major Saudi Arabian food manufacturing company giving them technical and commercial support over a wide range of confectionery areas:-
New product development
Operations improvement and equipment options
Improvement to existing products and manufacturing methods
Investigation of commercial alternatives in sourcing Cocoa
Reaction to proposed regulation changes
Project Valencia
Working with a start up company producing a unique, high quality Dairy and gluten free “milk” chocolates, beverage drinks and other confectionery based on Tiger Nut milk. Developing both products, manufacturing processes and manufacturing equipment and facilities. First products now on the local market in Spain.
Otions exist longer term to spread the technology to other Tiger Nut producing areas
Project QUAD
A major client producing a wide range of vitamin and mineral fortified gummy products wanted to quickly add innovation and interest to the product range as well as improving quality and consumer impact.
A range of options was developed which could be introduced without major investment but which would achieve the required objectives. This included a unique approach by using a non aqueous filling to protect the active components which normally degrade rapidly in a gummy formulation
Project Bee
A company which currently buys in a wide range of jelly type products for packaging under their own label wants to produce in house to improve quality control and reduce cost. We developed a project strategy for this starting from recipe development through to manufacturing concepts
Project Turkish
This involves the formulation of a novel product similar to Turkish Delight but using different flavours and presentations
Project Tiger
An entrepreneur is planning to manufacture a non dairy based beverage drink and ultimately confectionery using a locally produced (Spain) novel dairy alternative. This has required recipe formulation and process design, equipment design and specification and procurement with commissioning to be undertaken shortly. This novel project has been very well planned and is expected to be highly successful
The main product is now in production and we have developed a number of other vegan and gluten free products including a “milk chocolate”, caramels, fudge, butterscotch and hazelnut spread
Project Compound
A major Gulf based chocolate manufacturer wanted to consider moving some of its coated products to compound (ie using CBE/CBS/CBR) rather than chocolate per se. A series of recipes have been developed and samples prepared and tasted with the client. This will move forward to manufacturing in the near future
Project Line
Investigation into the viability of a major company moving to in house manufacturing of a range of peanut butter products. This included establishing appropriate technology, capacity requirements and capital and operating costs to first level.
Project Gummy
With colleagues developing a series of highly innovative premium products in the gum and jelly sector. These innovative products combine a high quality pectin shell with a variety of fat based centres, including chocolates, peanut butter, coconut creme and other high quality centres with high levels of centre filling. This results in a range of highly innovative products which can be produced using developments of available manufacturing technology.
The use of fat based centres allows the inclusion of moisture sensitive active ingredients to be delivered in a shelf stable format and the rapid setting formulations reduce setting times allowing high outputs at reduced cost.
The project has resulted in a considerable number of innovations and broadened understanding in formulation, technology, control of manufacturing process (eg shape and location of centres) and equipment design and specification. Innovative photographic techniques have allowed very precise understanding of the role of formulation and equipment design in shaping and locating unit centres
Project Sticky
A large American company has had problems with “gummy” products becoming sticky in process and in the market place. A full investigation of ingredients, formulations and process operations was undertaken to identify the factors causing the problems and suggest remedial measures.
Project Transform
A major Gulf based chocolate manufacturer wishes to transform the flavour of its chocolate in order to separate it from the other products in the market place. The concept is to move the flavour towards that typical of UK/Australia/New Zealand manufacturers without the high capital investment normally required for this
Project Expand
This project involves the complete review of confectionery operations for a major manufacturer in the Middle East. The project involves optimising existing products and recipes and designing and developing new products to broaden market appeal. It also involves a complete change in manufacturing scale and technology, including evaluation of equipment options, new plant layouts and operational studies.
Project Care
A substantial product and process development project for a major American Healthcare company. Involves innovative product design and the development of novel technologies with various equipment manufacturers to optimise the product and its performance. A number of very innovative concepts have ben combined to develop a radical new product for the client
Project Bench
A substantial benchmarking exercise for a major international confectionery manufacturer. The project involved the study and evaluation of a number of core chocolate making technologies in various global locations and producing recommendations on which technologies and suppliers should become preferred for the future. This has involved generating lengthy questionnaires and working closely with management, technical and procurement staff at various sites to gather a wide range of information. The evaluation has been based on scoring characteristics and performance as well as evaluating broader comments.
Project Phoenix
Equipment specification, process design and commissioning of a major new confectionery factory for one of the leaders in own label confectionery products.
Following a factory fire the client needed to restore the capability and capacity it had previously had but with more modern technology and equipment. This required close analysis of the requirements and examination of the equipment available to provide the required capacity and capability within the constraints of the new factory building and modern requirements for health, safety and hygiene. Extensive equipment tests were undertaken to identify operating procedures and conditions before equipment selection and specification. When the equipment was installed the equipment and processes had to be commissioned to required quality and performance standards
Project Fusion
Process audit to ensure technical compliance and good manufacturing practice for a manufacturer of synthetic sweeteners in India. Subsequent studies on costs and manufacturing efficiency
A venture capital company planned to launch a new synthetic sweetener in competition with the established manufacturer using expired patent technology. In order to ensure compliance it was necessary to audit and monitor the process technology being used and to integrate new technologies into the manufacturing plant as they became available.
A close working relationship was established with the Indian company involving R&D and Manufacturing functions in order to establish that correct procedures were being followed and that the factory had the appropriate facilities for ingredient and waste handling. The project also examined the operation of the factory and ways in which costs could be significantly reduced. It was found that high proportion of the product cost was made up by the cost of the solvents needed for the process which were not being recovered. A program to develop a process for recovery of the major solvents was proposed to the company.
Project Heart
This interesting non food project involves the process development, manufacturing operation design and equipment specification for a novel product which requires technology similar to that employed in the food industry. I have been working closely with the client to develop and understand the novel manufacturing processes and to prepare cost and time estimates for board approval for the project. I have also negotiated with equipment suppliers on his behalf to avoid excessive equipment costs through over specification.
During the project we have had to make several changes to the basic manufacturing concept to achieve excellent product quality and performance. This has involved extensive test work at the client’s factory and working closely with his manufacturing and technical team. I have also had to locate and negotiate with other potential technology suppliers under confidentiality agreements as we have developed the project concept more thoroughly.
Project Dissolve
My client had a formulation for a radically new beverage product but lacked the knowledge of how to produce. I undertook process investigation work and carried out tests with a number of technologies to identify what options were available to produce the product. From this I was able to design and speciy the process equipment needed and develop a factory layout and initial costings.
Project Waverley
The client wanted to start a new, high quality, chocolate manufacturing business for both third party and retail products in a Middle Eastern country. The initial stages of the project inolved evaluating the client’s requirements in terms of appropriate technology and equipment and potential costs, technical and manpower requirements for the operation.
Product proposals, recipes and materials costings were prepared and equipment tests planned and executed with the client with a well known UK equipment manufacturer. Product samples were prepared for evaluation and discussions on equpment specification and performace undertaken.A process design and equipment cost estimate was then prepared for the client who is currently considering the financing of the project.
The project has involved extensive discussion with the clent drawing on my direct experience in his region as his ideas for products, markets etc. have evolved.
Project Wafer
The client manufactures a successful range of coated wafer products but needed to upgrade quality as well as resolving issues with the performance of the chocolate flavoured coating. Products, recipes and processes were examined and recommendations for changes to cocoa sources, fat mixes and manufacturing supplied together with revised coating recipes for short and longer term development. In addition a new coating was formulated for use on ice cream products. Because of the client’s location and budget, discussions have been undertaken using Skype rather than by direct visits.
Project Morsels
This is a concept development project aimed at developing a range of chocolate products produced using a simple technology which can be manufactured and sold by retailers who are franchised. These will be mainly coffee shops and similar operations where the product can be seen being made, sold as a snack on the premisis and also sold as a retail gifting and snacking product to take away. In pricnciple there is no reason why the concept cannot be extended to almost all retail outlets and even to mobile operations at sports and other events.
Project Steel – Small Factory Relocation
A small, specialised producer of a unique savoury product needs to relocate production from its current old and unsuitable building to more modern facilities with the opportunity of increased production.
I discussed their requirements at some length following a visit to the factory and prepared alternative layouts and costs for the new building as well as giving general advice on the facilities needed and what steps might be taken to increase production.
Small businesses are fragile and there is no point in planning an expensive scheme which will financially cripple the business. Careful consideration of what is essential needs to be combined with a realistic insight into the resources available
Project Kenya
Free study for a charity on the possible use of Water Hyacinth as a fuel
Water Hyacinth is a major problem on tropical lakes and rivers as it grow vigorously and blankets the water surface making navigation and fishing almost impossible. Harvesting and drying the material would provide an alternative to increasingly scarce wood for domestic fires in remote areas.
Based on previous experience I was able to suggest the use of crushing and solar drying processes developed previously for other applications and in addition to propose the use of the sap from the crushing process as a feed material for a multi stage fish farming process originally used to treat rubber processing effluent in the far east.