Food Product Formulation & Manufacturer Selection

Phase 1 – Formulation Development

Step 1: Define Product Brief

• Objective: Capture the “north star” of the product so all stakeholders are aligned.

• Actions:

  1. Write down target macros: ~25g protein, <3g sugar, ~210 kcal per bar.

  2. Define desired flavour profile: peri-peri spice heat + peanut crunch + subtle sweetness from dates.

  3. List mandatory claims: vegan, gluten-free, clean label, no artificial flavours/preservatives.

  4. Decide shape and size: elongated 60g bar individually wrapped, matte-black & fiery packaging.

• Output: A one-page product brief (vision + specs).

Step 2: Ingredient Sourcing Research

• Objective: Identify reliable, scalable suppliers.

• Actions:

  1. Identify protein sources: pea protein isolate, peanut protein flour, roasted peanuts.

  2. Secure functional ingredients: chia seeds (fiber/omega-3), dates (binder + natural sweetness), stevia (low-calorie sweetener).

  3. Source spices: peri-peri seasoning, cayenne, black salt, turmeric, ashwagandha, moringa (for Ayurvedic positioning).

  4. Check supplier certifications: non-GMO, Organic, BRC, ISO, Halal/Kosher.

  5. Map supply chain costs: cost/kg, MOQ, shipping lead times.

• Output: Supplier shortlist with pricing, certifications, and lead times.

Step 3: Initial Bench Formulations

• Objective: Develop first working prototypes.

• Actions:

  1. Hire or consult with a food technologist.

  2. Create small test batches (100–200g each) with varying spice levels (mild/medium/hot).

  3. Test binders (date paste vs. brown rice syrup vs. agave).

  4. Check texture: soft chew vs. crunchy bite.

  5. Record process: mixing ratios, temperatures, moisture control.

• Output: 3–5 bench samples with documented recipes.

Step 4: Sensory Testing

• Objective: Validate consumer appeal early.

• Actions:

  1. Recruit 15–20 testers (target: Indian diaspora fitness enthusiasts + clean snackers).

  2. Blind test prototypes alongside competitor bars.

  3. Collect structured feedback: flavour, heat level, aftertaste, texture, satiety.

  4. Record quotes for future marketing (e.g., “Finally a protein bar that bites back!”).

• Output: Ranking report with clear winner formulation.

Step 5: Nutritional & Shelf Stability Testing

• Objective: Ensure claims hold up and product is shelf-ready.

• Actions:

  1. Run lab analysis for protein, carbs, sugar, fiber, fat.

  2. Use accelerated shelf testing (e.g., 45°C chamber for 6 weeks = 6 months real time).

  3. Test for microbial stability, rancidity (from nuts), moisture migration.

  4. Confirm “vegan” and “gluten-free” thresholds.

• Output: Nutritional panel, confirmed shelf life (ideally 9–12 months).

Phase 2 – Manufacturer Selection

Step 6: Identify Potential Manufacturers

• Objective: Build a list of co-packers capable of making FireFit.

• Actions:

  1. Search directories (ContractManufacturing.com, ThomasNet, NutraScience Labs).

  2. Attend trade shows (IFT, Fi Europe, SIAL) to meet co-packers.

  3. Use LinkedIn and industry groups (bar manufacturers in US/UK).

  4. Prioritize those with plant-based/vegan lines + allergen management.

• Output: Shortlist of 5–7 manufacturers.

Step 7: Issue RFI (Request for Information)

• Objective: Collect comparable data.

• Actions:

  1. Send 1-page product brief to shortlisted manufacturers.

  2. Request info:

     • MOQ & scalability

     • Cost per unit (raw + packed)

     • Certifications (FDA, BRC, ISO, Vegan, Organic)

     • Lead times

     • R&D support (can they help tweak formula?)

• Output: Responses for cost + capability comparison.

Step 8: Compare Manufacturers

• Objective: Select top candidates.

• Actions:

  1. Create evaluation matrix: cost, certifications, experience, MOQ, flexibility.

  2. Rank each factor out of 5.

  3. Highlight top 2–3 options for pilot run.

• Output: Manufacturer scorecard + shortlist.

Step 9: Pilot Run

• Objective: Test at scale.

• Actions:

  1. Arrange 500–1,000 unit pilot production.

  2. Observe texture, bar uniformity, packaging seal integrity.

  3. Distribute samples to testers + diaspora retail partners.

  4. Gather shelf stability data from real-world storage.

• Output: Pilot batch quality report.

Step 10: Finalize Agreement

• Objective: Lock in manufacturer partnership.

• Actions:

  1. Negotiate unit cost + volume discounts.

  2. Secure exclusivity clauses (prevent them selling FireFit clone).

  3. Define QA process: every batch tested for macros + microbes.

  4. Finalize logistics (warehouse, export paperwork, shipping).

• Output: Signed co-manufacturing agreement.

Phase 3 – Go-to-Market Readiness

Step 11: Packaging & Branding Finalization

• Objective: Ensure compliance + shelf appeal.

• Actions:

  1. Design wrapper with fire motif + diaspora spice cues.

  2. Add mandatory nutrition panel, allergen warnings, barcodes.

  3. Source compostable or recyclable film wrap.

• Output: Final print-ready packaging.

Step 12: Compliance & Certification

• Objective: Market clearance.

• Actions:

  1. Register with FDA (US) and FSA (UK).

  2. Apply for Vegan + Gluten-Free seals.

  3. File for export compliance (USDA, UK customs).

• Output: Approved certifications + regulatory clearance.

Step 13: Scale Production

• Objective: Move to launch quantities.

• Actions:

  1. Place initial production order (10,000–20,000 bars).

  2. Conduct batch QA testing.

  3. Ship to distributors (Amazon FBA, Indian stores in UK/US).

  4. Monitor sell-through + reorder cadence.

• Output: Product available for launch with QA sign-off.

✅ Final Outcome:

• A validated FireFit formulation

• Certified manufacturing partner

• Compliant packaging & shelf-stable product

• Scalable production pipeline to serve diaspora markets in the US & UK