Challenge
A small business was preparing to launch a new sauce line from a newly built food facility. Their in-house team had strong operational skills but lacked food science and food safety expertise. They also needed hands-on leadership to coordinate the project. I stepped in not only as a consultant but as a de facto manager, providing direction to the production team so they could move forward with clarity and confidence.
Approach
During onboarding I gathered all the critical details: formulations, manufacturing process, label designs, production volumes, staffing plans, facility and equipment capabilities, and go to market strategy. I started by drafting their Food Safety Plan, including a HACCP-style risk assessment and preventive control plan. In doing so I identified food risks inherent to the proposed formulation and process. I presented the client with options to bring the risk profile down to an acceptable level, and together we selected a practical solution that could be implemented quickly. This involved a formulation adjustment to achieve a lower pH as well as a process change to reduce time in the temperature danger zone. Because new ingredients were required, I sourced suitable regional distributors that fit their needs.
As a new facility, the company had no food safety policies or SOPs in place. I built these using my library of proven templates, tailoring each document to their specific operations. This ensured compliance with food safety, traceability, and GMP requirements while keeping the work efficient. With the safety and operating plan in place, I guided the client through working with state and federal agencies to secure the right permits for food manufacturing. In parallel I handled the product labeling, using a hybrid of measured and calculated methods to prepare nutrition facts, writing the ingredient statement, and finalizing all other label components.
Outcome
The company successfully passed their onsite audit and is now enjoying strong sales growth. This project was highly cost effective, as I was able to cover multiple roles including formulation, sourcing, food safety, regulator which allowed the client to avoid the expense and complexity of hiring several different specialists.
