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IAM International Inc

IAM International Inc. Team Project Members: Cecil Duncan Sachin Roopani Sylvia Ho. IAM International. A custom food manufacturing service provider for private label companies

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IAM International Inc

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  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. Ethnic foods mostly consumed by young professionals in metropolitan areas Since, 1960 3 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 Preliminary Market Analysis

  7. 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: $ 3.79-$1.81= $1.983/lb Economic Status and Forecast

  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

  11. Cost Analysis

  12. Cost Analysis

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

  14. Process Facility Diagram

  15. 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 • =

  16. Production Equipment • Scrape surface kettle • Automated fillers • HTST batch retorts

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

  18. 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

  19. 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

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

  21. 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

  22. 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

  23. 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

  24. 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

  25. 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

  26. 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)

  27. 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

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

  29. Job Progress Chart (wk1-17)

  30. Job Progress Chart (wk18-44)

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