BSM Partners Saves Client’s Launch Date and Eliminates $100k in Reformulation and Packaging Costs

The challenge

Retorted pet food products fall into two major categories: chunks in gravy and pate. A pate has a unique texture and is expected to be somewhat firm in shape, enough to hold its form when coming out of the packaging container. During a product commissioning, one of BSM Partner’s clients saw a change in consistency compared to previous product trials. The product came out too soft and, during visual evaluation, poured out of the container. Initially, the contract manufacturer believed the consistency was a result of a singular ingredient in the formulation and asked the client to:

• Assume responsibility for the financial value of the impacted product, which was over $100k.
• Reformulate the products, re-run trials, and update packaging, which was predicted to cost an additional $100k. This would have also prevented the client from meeting their launch date with retailers.

The solution

BSM Partners investigated changes in both formula and processing parameters between the product trials and commissioning. It seemed unlikely that the change in product consistency was ingredient-driven, especially when this ingredient had previously been used in successful trials. The investigation uncovered processing changes that were a likely culprit of the consistency changes including:  

1. The contract manufacturing location increased the drop temperatures from those previously established in the trials.
2. BSM Partners reduced the drop temperature to a more reasonable level to increase protein bind in the product.

The result

Changes in the drop temperatures resolved the consistency issues for the pates. The client met their launch date with retailers, which set the stage for successful future product launches. Additionally, the client avoided the costs incurred by reformulation and packaging changes, as well as financial responsibility for the impacted product.

The numbers

• Over $200k was saved in total between the impacted product and reformulation and packaging.
• The solution was provided at no added cost to product manufacturing.

BSM Partners

BSM Partners is a leading consulting firm in the pet and human food industries. BSM Partners is a collective of professionals across a wide variety of industries, backgrounds, and life experiences. We leverage our shared expertise for our clients and draw on our deep connections in the industry to help you succeed. We are prepared for every challenge your business might face. From product development to replenishment, we have you covered. Our services include research, consumer insights, product innovation, food safety and quality, regulatory, nutrition, veterinary, transformation, operations support, and engineering. With BSM Partners as part of your team, nothing is impossible!

About the author: David Perez works at BSM as Vice President of Product Innovation. His areas of expertise include formulation and product development, along with project management. Outside of work, David can be found playing tennis, making music, and watching scary movies.

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