Product Development Process - Simplified
Each step is defined but flexible.
Define Profile
Provide ingredient & claim recommendations.
Confirm cost parameters.
Establish critical parameter options, e.g., flavors, colors, texture, appearance, etc.
Complete project risk management & mitigation.
Propose primary package: form, servings per container, serving size, shelf life.
Competitive & intellectual property review (e.g., infringement & patentability
Formulation
Create “paper” theoretical formulas.
Evaluate raw material samples.
Evaluate theoretical cost models.
Ensure nutrient & active content levels.
Establish overage of claimed nutrients to meet shelf life & regulatory requirements.
Complete costing on different formula scenarios
Test
Final product & raw materials.
Claims substantiation.
Shelf life.
Packaging.
Physical, microbiology, chemistry, sensory, safety.
Competitive products.
Shakedown
Scale up to steady-state.
Validate manufacturing instructions.
Confirm throughput rate & costs.
Evaluate within-batch & batch-to-batch variability.
Define & confirm operating parameter ranges. (e.g., temperature, flow rate, mix time, etc.)
Ensure regulatory compliance. (e.g., thermal process, overages, nutrient ranges, etc.)
Prototype
Make samples using lab bench scale.
Prepare samples using pilot plant scale.
Evaluate process & package options.
Draft label & claims.
Complete formal & informal panel tests.
Complete accelerated stability studies.
Production
Robustness – Quality, output rate, defective rate.
Alternative raw materials qualification management.
Troubleshoot production anomalies.
Evaluate cost-saving opportunities.
Complete formal stability tests on regular production products.
Optimize quality testing.