Stuffed Boli Product Development Team Final Report

1. Stuffed Boli Product Development Team Final Report Elizabeth White Kelly Christiansen Daniel Markley April 30, 2002

2. Company Background • Philadelphia Fresh Bake Company • Originally located in Philadelphia, PA • All original selling venues were closed at current CEO’s purchasing of the company • Current manufacturing, at the FMT Rutgers Piscataway plant, is used to sell the product wholesale to large venues

3. Company Objective • Following our corporate slogan “We make it, you bake it”, the PFB’s aim is to provide a great tasting, stuffed baked good; striving for highest quality with minimal production costs.

4. Project Aims • Use current equipment at FMT facility • Use innovative methods to produce low cost food • Airline focus, increasing variety of products

5. Specifications Low cost Stuffed baked good Can be extruded Airline friendly Expand filling line Results Sloppy Joe Boli Grilled Veggie and Swiss Boli Broccoli and Chicken Surprise Boli Product Parameters

6. Customer Survey • People respond to stuffed dough products • Strongest association: • Hot Pockets • Currently not able to purchase our products in supermarkets

7. Demographic Sales Area Stuffed Bolies Convenience Stores Corporate Cafeterias Airlines

8. Products Developed • Kelly Christiansen • Grilled Vegetable and Swiss Boli • Elizabeth White • Sloppy Joe Boli • Daniel Markley • Chicken and Broccoli Surprise Boli

9. Kelly Christiansen • Grilled Veggie and Swiss Boli • Vegetarian • Low Fat • ‘A healthy alternative for people on the go!’

10. Elizabeth White • The Sloppy Joe Boli • Mess free • Definitely can be extruded • Intended to be very child friendly as this is normally a messy ‘kid approved’ meal

11. Daniel Markley • Chicken and Broccoli Surprise Boli • Surprise, it has cheese in it too • Good Aroma

12. Scaling Up of Product • Proposed production plan • See class handout • Major objective of our team was to keep costs to a minimum! • Used current FMT equipment • Minimized ingredient costs

13. Product Filling • The filling will be processed using a dual extruder. • High temperature and pressure will cook all filling materials • Some filling materials might be bought pre-cooked

14. Product Outer Shell • The outer extruder will be used to produce this part of the product • Ingredient mixing • Ingredient initial cooking • Product formation

15. Par-Baking • The partial baking of the product will be done via heat convection ovens • Ensures par-baking • Helps kill microbs • Creates initial browning of the product

16. Product Storage • The product will finally then be frozen via an air blast freezer • Helps to ensure microbial safety • Gives product longer shelf life • Finally the product will be frozen until cooked to be eaten

17. Product Storage • The product will be packaged two bolies per primary packaging • HDPE plastic • The secondary packing will be corrugated cardboard boxes • 60 per box if small • 40 per box if large

18. Cost Analysis Philadelphia Fresh Bake Co. Daniel Markley, Kelly Christiansen, Elizabeth White

19. Costs to Consider • General and Administrative • Equipment • Facilities • Employees • Product Cost • Ingredient Cost • Packaging • Storage • Transport

20. Equipment • Equipment Lease: $ 1,772.00 • Insurance (equipment and injury): $ 1,247.00

21. Facilities • Rent –includes storage (1 month): $ 3,335.00 • Office Supplies and Expenses: $ 67.00 • Depreciation Expense: $ 2,833.00

22. Employees - Monthly • Hourly Salaries: $ 1,750.00 • Management Salaries: $ 3,000.00 • Contract Labor: $ 667.00 • Payroll Tax Expense: $ 82.00 • Payroll Processing Fee: $ 667.00

23. Ingredients: dough ( water, sugar, salt, vegetable Ingredients: dough ( water, sugar, salt, vegetable oil, flour, bread base, colors and flavors), zucchini, oil, flour, bread base, colors and flavors), zucchini, yellow squash, portabella, olive oil, balsamic yellow squash, portabella, olive oil, balsamic vinegar, salt pepper. vinegar, salt pepper. Grilled Vegetable with Swiss Grilled Vegetable with Swiss Stromboli Stromboli Philadelphia Fresh Bake Co . Philadelphia Fresh Bake Co . “We make ‘ em – you bake ‘ em ” “We make ‘ em – you bake ‘ em ” Packaging and Transport 32 per case/ 9 oz 32 per case/ 9 oz • 1LDPE (2 per bag – 16,000): $ 320 • Corrugated Cardboard (32 per box): $600 / 1000 boxes (14.5 x 10 x 16) • Paper and Printing (per 1000): $ 1,583.33 • Freight and Delivery: $ 667.00 • Salesman’s Travel Expense: $ 60.00 1. http://www.sharppackaging.com/stockbaglist.html

24. Grilled Vegetable and Swiss Cheese Stromboli *Profits do not include general and administrative costs

25. Sloppy Joe boli *Profits do not include general and administrative costs

26. Broccoli and Chicken Surprise *Profits do not include general and administrative costs

27. Total Expenses (1000 cases / month) • Monthly Expenses (M): $ 18,650 • Veggie Monthly Expenses (30%): $5,595.10 • S. Joe Monthly Expenses (3750%): $699,375.00 • Chicken Monthly Expenses (9.375%): $ 1,748.44

28. Grilled Vegetable and Swiss Cheese Stromboli • Percent Monthly Expenses: $ 5,595.10 • Ingredient Cost: $ 2,400.00 • Total Expenditures: $ 7,995.10 • Total Sale: $ 8,640.00 • Net Profit: $ 644.90

29. Sloppy Joe boli • Percent Monthly Expenses: $ 699,375.00 • Ingredient Cost: $ 576,000.00 • Total Expenditures: $ 1,275,375.00 • Total Sale: $ 2,100,000.00 • Net Profit: $ 824,625.00

30. Broccoli and Chicken Surprise • Percent Monthly Expenses: $ 1,748.44 • Ingredient Cost: $ 2,190.00 • Total Expenditures: $ 3,938.44 • Total Sale: $ 2,700.00 • Net Profit: ($ 1,238.44)

31. Philadelphia Fresh Bake 120 New England Ave., Piscataway NJ 08854

32. Critical Control Points • Receiving of meat materials • Storage of meat materials • Cooling • Packing and Labeling • Storage of finished product

33. Objectives of HACCP Plan Once Critical Control Points are determined, the following steps must be carried out for each CCP • Determine Critical Limits • Monitoring of CCP’s • Record Keeping • Deviation Response • Verification

34. Receiving of meat materials

35. Storage of meat materials

36. Cooling

37. Packing and labeling

38. Storage of finished product