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IAM International Inc Team Project Members: Cecil Duncan Sachin Roopani Sylvia Ho.

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Presentation on theme: "IAM International Inc Team Project Members: Cecil Duncan Sachin Roopani Sylvia Ho."— Presentation transcript:

1 IAM International Inc Team Project Members: Cecil Duncan Sachin Roopani Sylvia Ho

2 IAM International A custom food manufacturing service provider for private label companies Services include: Product concept, Product formulation, Manufacturing, Quality control, Packaging, Warehousing, and Shipping Provides a turnkey operation

3 Team Objective To develop a novel, ethnic indian food to be marketed by IAM Intnl Product features include: shelf stability, maintain favorable organoleptic attributes, offer the convenience of a nutritious ready to eat food To see the product through initial prototype development to a feasible scale up process

4 Matter Paneer Fresh green peas & Indian cottage cheese in a creamy tomato based sauce flavored with garlic, onion, and a unique blend of spices and herbs.

5 Matter Paneer: Ingredients Water, tomato paste, diced tomatoes, light cream, canola oil, dehydrated onions, lemon juice, fresh ginger, fresh garlic, sea salt, paprika, dehydrated fenugreek leaves, cumin powder, corriander powder, turmeric powder, ground red pepper, clove powder, cinnamon powder Fresh paneer ( curdled whole milk, citric acid, salt) Green peas

6 Preliminary Market Analysis Ethnic foods mostly consumed by young professionals in metropolitan areas Since, out of 5 people added to the U.S population are non-white 10 years ago 65% dinners had home made item; today only 55%; number expected to decrease. Consumers surveyed not exposed to ethnic foods Hence apprehensive towards new ethnic foods- 85% would not purchase When prototype distributed 95% liked product enough to purchase Aggressive marketing needed to promote ethnic food

7 Economic Status and Forecast Annual sales $ 10M Costs: -Ingredients 56% -Labor and Misc 21% Profit for reinvestment 23% ie $2.3M Estimated profit from cost analysis for prototype: $65,934 Assumed production of 35,000 lbs annually Estimated profit per lb: sales-cost: $ $1.81= $1.983/lb

8 Marketing Potential Small niche based supermarket chains Ethnic grocery stores Health food stores Vegan markets

9 Process Viability Economical; technology available since 1970 Equipment used: Scrape surface, steam jacketed kettles, automated fillers, HTST Batch Retorts Cost of cycle per lb =$0.05

10 Cost Analysis

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13 Sautee Onions,Garlic, Ginger Delhi Korma Simmer Sauce. Mix. Preweigh Tomatoes,Spices, Cream,oil,Water

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15 Process Facility Diagram

16 Logistics Strategically located to highways, shipping ports, and railroads FMT close to NJ TWP, Rt 287, and Newark Port Authority Production contract fees moderate as facility located in industrial area =

17 Production Equipment Scrape surface kettle Automated fillers HTST batch retorts

18 Process Flow chart Weigh Ingredients Scrape Surface kettle Automated filler HTST Retort Package in Cardboard boxes

19 HTST Batch Retort Advantages: Container size, type and product flexibility Equipment failure for one retort does not stop entire production line Disadvantages: Batch process as compared to continuous, high labor cost, takes up a lot of space

20 Shelf life Stability Product retorted at 125C for 30min and 45 min Microbial testing performed on both batches biannually Sensory analysis conducted on each batch biannually Target microbes:C.botulinum and L.monocytogenisis. Gram-ve and +ve agarose plates used for testing

21 Quality Control & Assurance Implementations of: HACCP Plan Prerequsite Program Pre-Process Assurance In –Process Assurance Post-Process Assurance

22 Prerequsite Program Facilities –Proper Design, ventilation, waste disposal,lightening, handwashing Raw Material Controls –Specifications, supplier approval, receipt and storage, testing Sanitation –Pest control, environment control, chemical control Training –Personal safety, personnel GMPs, HACCP

23 Prerequisite Program Production Equipment –Cleaning/Sanitation, Preventive Maintenance, Calibration Production Controls –Metal Detection Program, Glass Control Storage and Distribution –Temperature Control, Transport Vehicle Cleaning and Inspection Product Controls –Labeling,Product Trace, Complaint Investigations

24 Pre-Process Assurance Inspect raw materials upon receiving for product quality e.g leakages, color Letters of guarantees for specific ingredients Weight up sheet for product formulations Screening on cleanliness of equipments e.g ATP assay Check and calibrate scales,detectors and equipments Check the monitoring records of storage temperatures

25 In-Process Assurance Laboratory ( For each batch) –Check for product specification: viscosity( Brookfield), pH( pH meter), % Brix, salt content, water activity ( water activity meter), color (mussel book of color) –Check for sensory attributes ( trained personnel) –Necessary adjustments will be made to meet specifications

26 In-Process Adjustments On-line inspection –Check temperature monitoring records of cooking, cooling and retorting process –Randomly check good fill weight and seal –Calibrate metal detectors

27 Post-Process Assurance Laboratory- random samples collected for each batch –Check for finished product specification –Microbial testing on finished product e.g total plate count( petrifilms), yeast and mold count( yeast and mold agar plate), Clostridium Botulinum, Listeria monocytogenes, Salmonella spps, E coli and Staphylococcus aureus. –Check for sensory attributes( trained personnel)

28 Post-Process Assurance Inspect correct codes, nutritional labeling, used by dates Check storage temperature monitoring records On-going shelf life studies for microbial count and sensory qualities Data are recorded, signed by operating personnel and checked by supervisors/managers before shipments Proper recording keeping for future recalls

29 Quality Improvement Continuous improvement Reduce cost defects Reduce inefficiencies Satisfy internal ( employees within company) and external customers

30 Job Progress Chart (wk1-17)

31 Job Progress Chart (wk18-44)


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