AboutJim Pfister Expertise Food Engineering/Manufacturing, Food Packaging/Distribution, Engineering Beverage Lines, Reducing operating cost of packaging lines while increasing efficiency. Lean Manufacturing. Incorporating new package technology into existing operations. Training staff to achieve smooth transition from "start-up" to full production. Managing complex projects across multi-disciplinary lines. Equipment PreShipment Factory Acceptance testing and Commissioning programs for new equipment.
Experience Employment history: Over thirty-five years of experience. Managed as much as $40MM in concurrent, multi-disciplinary projects, both domestic and international, and have worked with such firms as Campbell Soup, Coca-Cola, Hershey`s, and Nabisco.
Organizations: An author and speaker, as well as a member of the IoPP. Past Chairman of IoPP`s Consultant`s Council and Member of the Packaging Equipment Performance Committee.
Question QUESTION: I am starting a wing rub and sauce company and was wondering how I can make a product which does not need to be refrigerated after bottling. I am using dry ingredients, or ingredients that come off the shelf and not from a chiller or freezer (i.e. honey, garlic, soy sauce, etc). Any help would be greatly appreciated! Thanks so much!
ANSWER: Dennis,
Good morning.
I can only give you a general answer since I have incomplete info on your ingredients and your process.
What makes a bottle of sauce shelf-stable prior to opening is that both the product AND it's package have been sanitized or sterilized to a point permitting that to be done. For most of these products, that usually means hot filling at temperatures around 185 DegF or packaging it aseptically. Most home packaging or small volume operations can be made able to do the hot fill, but aseptic packaging equipment would be cost prohibitive for you.
I would recommend you do a Google on "home canning" which will show you lots of resources (equipment and other info). Once you have your business plan together, then you could look at private label or contract packers who could produce in larger volumes for you.
BTW, almost all of these products will still need to be refrigerated AFTER the bottle has been opened.
---------- FOLLOW-UP ----------
QUESTION: Thanks so much for your response. I apologize for not giving you all of the info, but you answered my question anyway. I followed up with the "home canning" information and I am confident it will work -- I will be sure to add safey handling instruction on the products.
As a follow up, if i was to marinade chicken in my rub and/or sauces, vaccuum seal the product and freeze, then sell the chicken to food establishments what are some general guidelines I should be aware for food safety? Any help on where to look as well would help greatly. Thanks again!
Answer Dennis,
The best advice I can give you is to closely monitor your distribution chain...particularly the times that are out of your control. Any product that needs special handling, be it freezing, refrigeration, or other, is vulnerable to people ignoring that or just being careless. I can't tell you how many times I've seen cases of stuff sitting outside on a dock - thawing - while waiting for the truck to show up.
While your initial volumes likely won't be that large, there will still be occasions where damage could get done. And, where a larger company may be able to withstand a recall, any bad press could kill a smaller guy like you.
