Project CSI

Project CSI-Group 8 Chilled Avocado-Cucumber Soup with Melon

A. Guthrie, H. Logsdon, W. Lv, J. Waldron, R. Zimomra

Project CSI-Group 8 2

Table of Contents

PRODUCT DESCRIPTION AND MARKET JUSTIFICATION................3 COMPANY IDENTITY.............................................................................................3

PRODUCT DESCRIPTION.......................................................................................4

TARGET MARKET AND CONSUMER..................................................................5

RETAIL PRICE AND PROFITABILITY..................................................................7

RAW PRODUCT...............................................................................................9 RAW INGREDIENTS SPECIFICATIONS AND STANDARDS.............................9

INGREDIENT HANDLING AND STORAGE........................................................12

PRODUCT FORMULATION...................................................................................14

INGREDIENT FUNCTIONALITY..........................................................................15

BATCHING PROCEDURES....................................................................................18

PROCESSING AND PACKAGING..............................................................20

PROCESSING JUSTIFICATION.............................................................................20

PROCESS DESIGN………………………………………………………………...22

PROCESS FLOW DIAGRAM..................................................................................25

EQUIPMENT SELECTION………………………………………………………..26

PROCESS QUALITY CONTROL............................................................................27

PACKAGING.............................................................................................................31

SANITATION............................................................................................................34

PRELIMINARY HAZARD ANALYSIS CRITICAL CONTROL POINT..............35

FINISHED PRODUCT....................................................................................38

FINAL QUALITY STANDARDS AND SPECIFICATIONS..................................38

ORGANOLEPTIC ANALYSIS.................................................................................40

NUTRITIONAL LABELING....................................................................................41

SHELF LIFE..............................................................................................................43

REGULATIONS AND REQUIREMENTS..............................................................45

FINAL COST ANALYSIS……………………........................................................45

FUTURE DIRECTIONS.................................................................................46

APPENDIX.......................................................................................................47

APPENDIX A: ACKNOWLEDGEMENTS..............................................................47

APPEDIX B: REFERENCES....................................................................................48

APPENDIX C: SPECIFICATION SHEETS.............................................................51

APPENDIX D: COST DATA....................................................................................79

Project CSI

Executive Summary

Guthrie, Logsdon, Lv, Waldron, Zimomra

Executive Summary

Our project this semester was to create an ultra-premium soup innovation for Campbell

Soup Company. The Campbell Soup Company is highly known for their authentic, homestyle

soup. However, when the warm summer months come, they often experience a decline in soup

sales. As Campbell’s continues to build on their strength as the leading soup maker, they also

have been greatly focused on expanding into new categories like packaged fresh foods and

simple, organic meals. In 2012, the Campbell Soup Company purchased Bolthouse Farms,

making it the largest acquisition in Campbell’s history. Bolthouse Farms is known for using high

pressure processing to create high quality products made from the freshest produce. As a way to

help increase summer soup sales, and accommodate the younger audience that the Campbell

Soup Company has recently begun to target, we decided to create a chilled Avocado-Cucumber

Soup with Melon and label it under the Bolthouse Farms brand. This product is intended to be a

happy medium between Campbell’s hearty soups and Bolthouse Farms healthy, fresh juices. It

will be positioned as a ready-to-eat meal in the refrigerator section of grocery stores, next to the

fresh produce. It is a healthy, on the go, refreshing meal for consumers who are looking for a

new and exciting product.

This ultra-premium soup is non-thermally processed with High Pressure in order to

obtain the highest quality possible. Because this is a non-thermal process, the nutritional value

and freshness is essentially fully retained compared to thermal processes. Currently, there is a

wide variety of HPP products out on the market. We chose to utilize HPP based off of similar

products on the market, pertaining to the avocado in our formulation. Products with avocado in

them, such as guacamole, have been successfully processed for years with HPP. High Pressure

Processing inactivates a large population of the enzyme polyphenoloxidase, which is responsible

for browning in avocados. Our product is safe for consumption because it is an acidified food,

having a pH of 4.2. It’s also refrigerated immediately after processing to further preserve quality.

In addition, the high pressures used during this process destroys yeasts, molds, and

microorganisms of concern such as Salmonella, Listeria monocytogenes, and Escherichia coli.

This chilled soup requires no preservatives because it is a high acid, High Pressure Processed

product which appeals to current consumer trends of clean labeling.

Project CSI

Executive Summary

Guthrie, Logsdon, Lv, Waldron, Zimomra

The packaging for our chilled-soup is extremely important because it is the first thing that

the consumer sees. If consumers do not like it, they will be less-inclined to purchase our

product. With that in mind, we have opted to go with a clear, 16.9 oz. PET bowl that will allow

the consumer to see the quality of our product prior to purchasing. The package will be sprayed

with a hydrogen peroxide solution and then filled, heat sealed, and lidded with an Osgood Inline

3600 E-L. The lid will be resealable, allowing consumers to store it in their refrigerator up to two

days after opening.

Since our soup is a premium product made with fresh ingredients, the quality and storage

of each ingredient is extremely important to the flavor and safety of our overall product. The

cucumbers, honeydew melon, and avocados must be checked for ripeness to ensure a consistent

flavor and texture. All ingredients are checked with their COA specifications for safety and

quality purposes. All ingredients are regularly tested for pathogens to prevent microbial

contamination in the soup. The storage of each ingredient is monitored to keep the ingredients in

the highest quality until processing. Each ingredient has a specific temperature and humidity

level that must be followed for optimal quality. Some ingredients also have ventilation or light

requirements. Once the raw ingredients are checked against their respective specifications, they

are prepared for processing. The batching procedures for processing include dry blending all

spices, removing the skins and pits of the avocados, dicing the cucumbers, and diluting the

concentrates with water. Each ingredient contributes an important function in the overall product.

Yogurt mainly contributes acidity and increases the protein content. Honeydew melon provides

sweetness. Water in cucumber, honeydew melon, and added water is solvent for other

ingredients. Avocado is high in monounsaturated fats which is appealing to consumers, which

can stabilize the product. Lemon juice concentrate is a preservative and decreases the pH which

ensures product safety. Sea salt is another preservative and is a salty flavor contributor. Onion

powder, pepper, cucumber and mint leaf powder are used to enhance the flavor.

The expected shelf life is 3 months and real time tests will be conducted. Temperature,

light and gravity are key attributes to the end of shelf life. Two kinds of sensory tests will be

conducted. Descriptive analysis is used to track sensory change over time, and consumer

acceptance test is used to collect feedback from consumers.


I. Product Description & Market Justification Company Identity

The Campbell Soup Company began in 1869 by Joseph A. Campbell, a fruit merchant,

and Abraham Anderson, an icebox manufacturer. At that point, Campbell was producing canned

tomatoes, vegetables, jellies, minced meats, condiments, and soups. When Anderson left the

company in 1876, Campbell renamed the company as “Joseph A. Campbell Preserve Company”.

John Dorrance, a chemist who discovered a commercial way to condense soup, worked his way

up to being the President of Campbell Soup Company and eventually bought out Campbell’s

portion of the company. It wasn’t until 1922 that Campbell adopted "soup" as its middle name,

and officially changed the company name to Campbell Soup Company. Today, Campbell’s is

headquartered in Camden, New Jersey. They make a range of products from high-quality soups

and simple meals to snacks and healthy beverages. Though most commonly recognized for their

authentic, family-style soup, the Campbell Soup Company extends beyond soup. They own

Pepperidge Farm cookies and Goldfish crackers, Swanson broths, Prego pasta sauces, Pace

Mexican sauces, Arnott’s, Kjeldsens and Royal Dansk biscuits, V8 beverages, and most recently,

Bolthouse Farms super-premium beverages, carrots and dressings. They have annual sales of

more than $8 billion, which is led by the Campbell’s brand with $2.1 billion. (Campbell’s)

In 2012, the Campbell Soup Company purchased Bolthouse, making it the largest

acquisition in Campbell history. Bolthouse Farms Company was founded in 1915 and is located

in San Joaquin Valley, California. As soup sales have slowed, this acquisition has allowed

Campbell to expand its beverage offerings and focus on augmenting their healthy drink options.

As Campbell continues to build on their strength as the leading soup maker, they also have been

greatly focusing on expanding into new categories like packaged fresh foods and simple, organic

meals. As stated by Campbell CEO Denise Morrison, “Bolthouse is a great strategic fit with

Campbell. Its business platforms, capabilities and culture are aligned with the core growth

strategies we announced last year.” This acquisition has allowed Campbell to bring in a younger

audience and accommodate a wealthier taste palette. (Sweeney 2012)

Bolthouse Farms is known for high-quality consumer brands and innovative products.

They believe in healthier and affordable food choices, fresh thinking, high quality, and great

tasting products. Currently, they produce and sell super-premium juices, smoothies, protein

shakes and café beverages. They are also one of the United States leading producers of carrots.


In recent years, Bolthouse Farms has diversified its offerings by launching a line of premium

refrigerated yogurt dressings and extra virgin olive oil vinaigrettes. The mission of Bolthouse

Farms is to Inspire the Fresh Revolution and to change the way people consume healthy foods

and beverages. As a way to incorporate a fresh, healthy meal option into the Campbell Soup

Company current market offerings, our chilled avocado-cucumber soup with melon will be

branded under Bolthouse Farms

Product Description

Bolthouse Farms Chilled Avocado-Cucumber Soup with Melon is a blend of fresh

avocados, honeydew melon, cucumber, mint, low-fat yogurt and various other seasonings. Our

product is a ready-to-eat (RTE) liquid product that is high-pressure processed and is distributed/

sold refrigerated. It will be packaged in a 16.9 oz. clear plastic container containing two serving

sizes. The clear package will catch the consumer’s eye because they will be able to see the

bright and fresh mint-green color of our soup. This soup, as briefly mentioned before, is pureed

and high-pressure processed to ensure maximum flavor and color retention. It is chilled

immediately after processing and distributed while refrigerated. It incorporates the same fresh

fruits and vegetables that are used to make Bolthouse Farms premium beverages. This will be a

focal point Campbell’s will use when positioning their product under the Bolthouse brand.

Chilled soups have a strong health positioning and provide an alternative to fruit and vegetable

juices that are often perceived by consumers as containing too much sugar.

Bolthouse Farms Chilled Avocado-Cucumber Soup with Melon contains only 130

calories per serving (240g) and 8 grams of sugar. The fiber from the avocados makes this a

filling, yet light meal. Each package contains two 240g servings and has a resealable lid,

allowing consumers to store it in their refrigerator for up to 2 days after opening. This product is

intended to be the fusion of two iconic brands; Campbell’s hearty soups and Bolthouse Farm’s

fresh juices. It is a healthy, on the go, refreshing meal for consumers who are looking for a new

and exciting product.

Target Market & Consumer


Cold soup is a trend that is gaining popularity in the United Kingdom, though it has yet to

make a heavy impact on soup sales in the United States. In fact, refrigerated/frozen fresh soups

only account for 4% of the prepackaged soup market in the United States (Mintel, 2013).

According to a report by Amy Kraushaar, US Food and Drink Category Manager for Mintel,

consumers are expecting more out of the soup industry. Consumers as of February 2014 want to

see: full servings or more of vegetables (89%), low sodium (80%), vitamins and minerals (79%),

high fiber (79%), no preservatives (76%), and more superfoods (56%). We tried our best to

accommodate as many of these as we could, but with further research and development, we

believe we could do even better.

The concept of cold soup is not a revolutionary one. Not only is it well-established in

several European countrie, where the warmer climate helps increase the appeal of chilled soups,

but according to Mintel, refrigerated/frozen wet soups are forecasted to have a solid and steady

growth into 2018 (Mintel, 2014). What better time than now to introduce chilled soups into the

US market?

The overall chilled soup category has increased in value by an impressive 25% between

2010 and 2012, to account for approximately a third of the wet soup market in the UK. Unlike

the UK, the United States soup manufacturers currently have a significant decrease in sales

during the warm summer months. Thus, cold soups provide an opportunity to reduce soup’s

winter season sales dependency. As shown in Figure 1, below, younger consumers in the UK

express noteworthy interest in cold soups (Mintel 2013).


Mintel February 2013. Base: 1,272 Internet users aged 16+ who have eaten or bought soup in

the last 6 months

Figure 1. Agreement with the statement “I like the idea of eating cold soup (eg Gazpacho) in

hot weather” by gender, age, and socioeconomic group.

With the recent acquisition of Bolthouse Farms, the Campbell Soup Company has strived

to attract younger audiences. Thus, this product will be targeted towards younger consumers,

males and females ages 25-34. According to Mintel, this age demographic is more interested in

buying natural, organic, or protein-rich soup, and are less interested in fat, salt, or caloric

content. Consumers under the age of 35 are more likely to express interest in cold soups, being

that they have a more experimental approach to food in general. Consumers want to see soups

with more nutritious ingredients and “super foods.” Our product will be packaged in a

convenient package to target the busy, young professionals who are on the go. They are willing

to pay more for quality or premium brands, and seek out healthy foods.

The primary distribution channels for soups are supermarkets and grocery stores. Thus,

the target retailers of our product will be chain supermarkets and grocery stores - particularly,

health-food grocers such as Whole Foods and Trader Joes. It will be placed in the refrigerator

section of the produce section, directly next to Bolthouse Farms healthy beverage options. By

positioning this product in the fresh produce section of grocery stores; consumers will perceive it

as a healthy and nutritious meal option. “Shoppers likely perceive refrigerated soups to be


fresher and less processed than shelf-stable and dry soups. The trend toward fresh ingredients

can help drive sales of refrigerated soups in the coming years” (Mintel 2013). Based off of when

new smoothie flavors are launched, the product will be released in mid-March to early April,

when spring has just begun and the weather is slowly beginning to warm up. Consumers are

looking for something refreshing to get them in the warm weather mood and we believe our

product will be a go-to.

Retail Price & Profitability

Although price is important, quality is the focal point of current soup competition. There

is a strong demand for soups providing nutritional value and quick preparation along with

affordable prices. Within the soup market, quality tends to mean lower sodium content and

higher-quality ingredients. Health-oriented brands and labels are becoming increasingly strong,

thus, consumers are willing to pay more for the quality offered in premium products. We have

priced our product based off of ingredient and production costs, and current Bolthouse Farms

smoothie and juice prices. The ingredient costs to make this product are outlined in Table 1, and

the unit cost in Table 2. The selling price per individual container will be $4.99.

Our product is considered a high margin, low volume product. Current Campbell

products are low margin, low volume products averaging between $1.49-$1.69 per can

containing 2.5 servings. Our product, on the other hand, will be sold in a 16.9oz container

containing 2 servings for $4.99, which costs us $.539 to produce. Although our distribution will

be more expensive due to the needed refrigeration, our margins will be significantly higher than

canned counterparts. Refer to Table 3 for a breakdown of our cost structure.


Table 1. Ingredient Cost

Ingredient Percentage/100g

(%)

Percentage/

Package

(240g)

Percentage/

Package

(kg)

Cost/

Package

($)

Yogurt-Plain, low-fat 29.60 71.04 0.07104 $0.125

Honeydew Melon 23.50 56.40 0.05640 $0.093

Cucumbers-Seedless 15.00 36.00 0.03600 $0.045

Vegetable Stock Base 15.00 36.00 0.03600 $0.010

Hass Avocado 13.30 31.92 0.03192 $0.046

Lemon Juice Concentrate 2.60 6.24 0.00624 $0.175

Pure Ocean Atlantic Sea Salt 0.40 0.96 0.00096 $0.002

Onion Powder 0.30 0.72 0.00072 $0.004

Peppercorn-Ground 0.20 0.48 0.00048 $0.007

Mint Leaves Powder 0.10 0.24 0.00024 $0.002

Water 0.00 0.00 0.00000 0.000

Total Ingredient Cost per

Package

$0.509

Table 2. Unit Cost

Component Cost ($)/Unit Cost ($)/ Batch

Product 0.509 2122.70

Package 0.030 124.98

Total 0.539 2247.68

Table 3. Cost Structure

Cost Structure- High Margin, Low Volume Product

Component Composition (%) Cost ($)/

Package

Cost ($)/ Batch

Production Cost 38% 0.19 $854.12

Net Profit 33% 0.17 $741.73

Marketing & Admin. 16% 0.08 $359.63

Distribution 8% 0.04 $179.81

Other 5% 0.05 $112.38

Final Product Cost 100% 0.53 $2,247.68


II. Raw Product Ingredients Source, Standards, and Specifications

Table 4. Raw Product Ingredient Sources and Specifications

Ingredient Supplier Specifications from

COA

Specifications

to be tested

Price &

Unit Size

Hass

Avocados -

raw, partially

ripened, size

84

Henry

Avocado

Corporation

Dry matter: 21-35%

Enterobacteriaceae:

<500/g

E. coli <10/g

Yeast and Molds:

<5000/g

Salmonella: Neg/25g

Staphylococcus: Neg/25g

Listeria monocytogenes:

Neg/25g

Ripeness

checked with

penetrometer:

≤ 1.5 lbf.

E. coli: < 10/g

Salmonella:

Neg/ 25g

Listeria

monocytogenes:

Neg/ 25g

$0.65/ lb.

25 lb. box

Cucumbers –

seedless

Worldwide

Produce

Brix: 2.2-5.4°

TPC: 100,000/ g

Enterobacteriaceae:

<500/g

E. coli <10/g

Yeast and Molds:

<5000/g

Salmonella: Neg/25g



Neg/25g

E. coli:

< 10/g

Salmonella:

Neg/25g

Listeria

monocytogenes:

Neg/25g

$0.55/lb.

25 lb. box

Honeydew

Melon –

frozen chunks

Superior Foods

International

Brix: 10-14°

TPC: 100,000/ g

Enterobacteriaceae:

<500/g

E. coli <10/g

Yeast and Molds:

<5000/g

Salmonella: Neg/25g



Neg/25g

E.coli: < 10/g

Salmonella:

Neg/25g

Listeria

monocytogenes:

Neg/25g

$0.75/lb.

30 lb. case

Lemon Juice

Concentrate

Northwest

Naturals

Brix: 48° min

Titratable acidity: 390-

410g/l

pH: 2.4-2.9

TPC: 2000 cfu/ml max

Yeast: 1000 cfu/ml max

Mold: 50 cfu/ml, max

pH: 2.4-2.9 $45.00/gal

50 gallon

drum


Mint Leaves

Powder

The Food

Source

International

Inc.

Moisture: 10% max

Volatile oil: 1% min

TPC: 100,000/g max

Yeast & Mold: 500/g

max

Coliforms: 500/g max

E. Coli: <10/ g

Salmonella: negative

E. coli: <10/g

Salmonella:

Neg/25g

$3.20/lb.

50 lb. bag

Onion Powder The Food

Source

International

Inc.

Moisture 7% max

Total Ash 8% max

Acid Insoluble Ash 2%

max

Aerobic Plate count

25,000/g max

Yeast & Mold: 400/g

max


E. coli: negative in 11g

Salmonella: negative in

25g

E. coli: Neg/11g

Salmonella:

Neg/25g

$2.50/lb.

50 lb. bag

Peppercorn -

Ground

The Food

Source

International

Inc.

Moisture: 12% max

Volatile oil: 2% min

Total Ash: 7% max

Acid Insoluble Ash: 1%

max

Aerobic Plate count

25,000/g max

Yeast & Mold: 400/g

max


E. Coli: negative in 11g

Salmonella: negative in

25g

E. Coli:

Neg/11g

Salmonella:

Neg/25g

$6.95/lb.

50 lb. bag

Pure Ocean

Atlantic Sea

Salt (Fine:

0.2-0.6mm)

SaltWorks Inc. Moisture: <0.5%

NaCl: 97% minimum

Salmonella: negative

Listeria: negative

Staph Aureus: negative

E. coli: negative

Salmonella:

Neg/11g

Listeria:

Neg/25g

E. coli:

Neg/ 25g

$0.78/lb.

55 lb. bag

Vegetable

Stock Base

RC Fine Foods Salmonella: negative

Listeria: negative

Staph Aureus: negative

E. coli: negative

Salmonella:

Neg/11g

Listeria:

Neg/25g

E. coli:

Neg/ 25g

$7.30/lb.

30 lb. pail

(yield 6.67

gal)


Yogurt –

Plain

The Dannon

Company, Inc.

Fat: 0.5-2%

Milk Solids Not Fat: min

8.25%

Coliform: <10/g

Yeast and Molds: <50/g

pH: < 4.5

Coliform: <10/g

Yeast and

Molds: <50/g

pH: < 4.5

$0.80/lb.

50 lb. bag

Water

(municipal) –

softened,

filtered (5µ),

activated

carbon

filtered

The

Metropolitan

Water District

of Southern

California

Total solids: up to 500

mg/l

TPC: 100 CFU/ ml

Total Coliforms: < 5%

Viruses (enteric): 99.99%

killed/inactivated

Giardia lamblia: 99.99%

killed/inactivated

pH: ~7

chlorine: < 4ppm

Total

Coliforms: <

5%

Viruses

(enteric):

99.99%

killed/inactivate

d

Giardia lamblia:

99.99%

killed/inactivate

d

pH: ~7

chlorine: <

4ppm

$0.03/gallon


Ingredient Handling & Storage

Table 5. Raw Ingredient Handling and Storage

Ingredient Storage Conditions Shelf Life

Hass avocados - whole Pre-ripened:

18-20°C until fully ripened

85-95% humidity

Air circulation (1000

cfm/pallet)

No direct sunlight

Keep CO2 level below 1%

Ripened:

5-7°C (minimum 5° C to avoid

chill damage)

85-95% humidity

No direct sunlight

3-10 days (depending on

stage of ripeness)

2-3 days

Cucumbers – whole, seedless 10-13° C

95% humidity

No direct sunlight

Keep away from high-

producing ethylene products

5-7 days

Honeydew melon – frozen

chunks (processed)

Frozen:

-18°C

5 cm minimum between cases

for air ventilation

Thawing:

10-13° C

Up to 2 years

2-3 days

Lemon juice concentrate –

undiluted

-17-18° C (drums not being

used)

4° C

Up to 1 year

Mint leaves ( dehydrated,

crushed)

10-22°C

< 15% humidity

Adequate ventilation

Dry environment

Away from odor-producing

ingredients/materials

No direct light

Up to 2 years

Onion powder 10-22°C

< 15% humidity


Dry environment

No direct light

Up to 2 years

Black peppercorn (ground) 10-22°C Up to 2 years


< 15% humidity


Dry environment

No direct light

Sea salt (fine) 10-22°C

< 15% humidity


Dry environment

No direct light

Up to 2 years

Vegetable stock base 10-22°C

< 15% humidity


Dry environment

No direct light

Up to 1 year

Yogurt – plain, low-fat 1-4°C 18 days


Product Formulation

Table 6. Product Formulation

Ingredient Percentage (%)

Based on weight

Weight for 1000 kg

1000kg = 1 batch = 4,166

packages

Yogurt – plain, low-fat 29.60 296.00

Honeydew melon 23.50 235.00

Cucumbers – seedless 15.00 150.00

Vegetable stock 15.00 150.00

Avocados 13.30 130.30

Lemon juice 2.60 26.00

Sea salt – ground 0.40 4.00

Onion powder 0.30 3.00

Pepper –ground 0.20 2.00

Mint 0.10 1.00


Ingredient Functionality in Product

Yogurt (plain, low-fat) – Yogurt contains two main ingredients: lactic acid bacteria and, in our

case, low fat milk. The yogurt that we are using contains pectin, which is a stabilizer not only

for the yogurt itself, but in turn, a stabilizer for our soup (Christina, 2011). The pectin will help

to create a uniform product by suspending our particulates so that they do not separate upon

distribution and storage. In addition, it will allow our product to look appealing to consumers.

Yogurt is high in protein, containing 8g of protein per serving (170g). When this protein

structure is broken by blending, protein is able to interact with the other constituents in the soup.

One interaction the protein undergoes is absorbing/binding fat (mostly from avocados) creating a

structure that makes our soup homogeneous (Zayas, 1997). In addition to binding fat, proteins

bind with water (in our case, vegetable stock) and makes the water inseparable with a centrifuge

(AKA helps the soup to remain creamy and homogenous) (Zayas, 1997). Protein also adds a

nutritional value that is highly appealing to customers when they see it on the nutrition label.

Yogurt also has a low pH creating a high acid environment, which inhibits harmful microbial

growth. The high acidity also contributes a sour flavor to the soup.

Honeydew melon – Honeydew melon contains a combination of sugars including sucrose,

glucose and fructose (Davis, 1995). One serving of honeydew (177g) contains 14g of sugar

which contributes sweetness to the soup. This sugar is important because it binds with water and

helps to create the textural components of our soup. Furthermore, large amounts of water

contained in the honeydew serve as a solvent for other ingredients such as, onion powder and

salt. Honeydew also contributes to the fresh green color and gives a particulate mouthfeel, which

we are aiming for because we want out consumers to taste and see all of the nutritious

ingredients in our soup.

Cucumber (seedless) – Beyond flavor, cucumbers provide large amount of water which acts as

a solvent for ingredients such as onion powder and salt. They only contain 8 calories per serving

(52g), but due to the fact that they are blended in our soup with their peel, they contribute a little

bit of dietary fiber. Their main functionality is flavor, their green color, and a particulate texture.


Water – Water, as stated earlier acts as a solvent and allows chemical reactions to occur. Water

is added to dilute our lemon and vegetable stock concentrates. When added with concentrates, it

helps our soup to have a consistent texture, flavor and acidity. It is a main factor in perishability

and preservation of food.

Vegetable stock base – The organoleptic compounds in the stock enhance flavor. In addition,

vegetable stock is our main source of water and acts as a universal solvent that helps to combine

the ingredients of the soup and make it into a consistency that is indicative of soup. Vegetable

stock greatly increased the sodium content in the soup, which as stated early, imparts flavor, but

also serves as a natural preservative. Sodium is extremely important in our product because we

do not have any other preservatives therefore, after opening it helps to keep microbial growth

slower.

Avocados (Haas) – Without the avocados, our soup would have no stability. The

monounsaturated fat from the avocados, in combination with the protein from the yogurt interact

to form a stable structure that keeps our soup homogenous (Zayas, 1997). Avocados are

appealing to consumers who are looking for superfoods in their nutrition labels and it provides

healthy fats (monounsaturated) and dietary fiber that will help to keep consumers fuller longer.

Avocados contain nearly 20 vitamins including potassium, lutein, folate, as well as, B, C and E

vitamins (USDA database/“Everything you need…”). Beyond the nutritional benefits, avocados

contributes to the creamy, rich mouthfeel of the soup and to the fresh green color.

Lemon juice concentrate – Lemon juice contains citric acid that helps decrease pH value,

making our product high-acid and in turn, safe to high pressure process. Citric acid is a kind of

preservative that helps increase the length of shelf life. Lemon juice also prevents browning of

avocados by polyphenol oxidase because of a combination of its ascorbic acid (Vitamin C) and

low pH. The ascorbic acid stops browning because it creates a barrier between the polyphenol

oxidase enzyme and oxygen. The PPO will first react with the acid instead of the oxygen. The

low pH impacts the browning reactions because polyphenol oxidase functions best at pH levels

between 5.0-7.0. When lemon juice (pH 2.0) is introduced to the system it lowers the pH


knocking the PPO out of its ideal pH range (“Why lemon..”). The lemon juice also contributes to

the sour flavor, as well.

Sea salt – Sea salt contains sodium chloride that contributes the salty flavor. It’s used as

preservative to increase shelf life and increases sodium content of the soup. Salt plays a role in

several chemical reactions.

Onion powder – Onion powder contributes the onion flavor and serves as a natural

antimicrobial agent and source of antioxidants (Aguirre, 2012).

Pepper (ground) – Pepper enhances the flavor of the soup.

Mint leaves (powder) – Mint is used to enhance and compliment the flavor and adds textural

particulates.


Raw Product Batching Procedures

Spices 1. Onion powder (26 kg), mint powder (0.7 kg), sea salt (4 kg), and ground pepper (20 kg)

are measured manually by weight.

2. Spices are sent through sieve to remove any foreign material and to help loosen lumps.

3. Spices are loaded into double cone blender for dry blending and collected into Hopper 1.

Hopper 1 is wheeled to Blender 1.

Avocados

1. Ripe avocadoes are sent through flume washer with chlorine treated water (150 ppm)

and rinsed again with municipal water.

2. Rinsed avocados are cut in half by slicer.

3. Skin and pits are removed manually from halved avocados.

4. Avocado flesh (130.40 kg) is moved along conveyor belt and collected into Hopper 2.

Hopper 2 is wheeled to Blender 1.

Cucumbers

1. Cucumbers (150 kg) are washed in flume washer with chlorine treated water (150 ppm)

and rinsed again with municipal water.

2. Rinsed cucumbers are sent through dicer (½ by ½ inch pieces) and collected into Hopper

3. Hopper 3 is wheeled to Blender 1.

Honeydew Melon

1. Thawed honeydew melon (235 kg) is received from refrigerated storage and loaded into

Hopper 4. Hopper 4 is wheeled to Blender 1.

Vegetable Stock

1. Vegetable stock concentrate (2.71 kg) is loaded into Mixing Tank 1.

2. Water (147.29) is pumped into Mixing Tank 1 and mixed with vegetable stock

concentrate.

3. Diluted vegetable stock (150 kg) is pumped to Blender 1.


Lemon Juice

1. Lemon juice concentrate (26 kg) and water (234 kg) are pumped to Mixing Tank 2.

2. Concentrate and water are mixed in Mixing Tank 2.

3. Diluted lemon juice is pumped to Blender 1.

Yogurt

1. Yogurt is pumped into Blender 1.

Blending

1. Avocado flesh, diced cucumbers, melon chunks, and spice mixture are loaded into

Blender 1.

2. Mixture is blended until smooth consistency is achieved, 20 minutes.


III. Processing & Packaging

Process Justification

Our process for manufacturing our chilled soup was thoroughly justified by running pilot

plant trials in which we utilized two different types of thermal processes and one type of non-

thermal process. The first type of thermal process we experimented with was HTST using a

Microthermics unit. Knowing that we wanted to label our chilled soup under the Bolthouse brand

and deliver an ultra-premium product, our goal was to emulate their process. We chose HTST

upon researching how Bolthouse manufactures their beverages, which is done with flash

pasteurization. Since our soup is an acidified product, we chose to process at a time and

temperature similar to one found from a study done on a tomato soup in the Institute of Food

Technologists Journal of Food Science (Colle et al., 2011). Based off of this journal article, we

processed our soup at 203°F for 7.5 seconds. We hypothesized that the avocado would turn

brown due to the high temperature heat treatment and that the cucumber might produce off

flavors. After processing and performing visual and analytical tests, we found that our hypothesis

was correct. We observed thermal browning of the avocado as well as off flavors and odors from

the cucumber and avocado.

The next thermal process we tested in a pilot plant trial was LTST with a Sous Vide. We

hypothesized that the lower temperature might allow us to successfully process the soup without

any color or flavor problems arising. Two different trials with the Sous Vide were performed.

The first trial was done at 140°F for 45 minutes and the second trial was done at 150°F for ten

minutes. These processing parameters were validated with information on safe cooking times

and temperatures provided in the Sous Vide manual. Upon completion of these two trials, we

found that both of the soups had browning and off flavors. After observing the data from

analytical tests performed on the soup made in the LTST trial, we concluded that this process

was a better option than HTST. However, the LTST trial did not provide the quality attributes we

were looking for. At this point, we knew that thermally processing our soup was not an option

due to the avocado and cucumber resulting in poor quality attributes when treated with heat.

Our next step was to run a third pilot plant trial using a High Pressure Press to

manufacture our chilled soup. Our processing parameters chosen were based off of research done

on inactivation of the enzyme polyphenol oxidase, lipoxygenase activity, standard plate, yeast

and mold counts, as well as sensory acceptability and color in guacamole utilizing High Pressure


Processing. The research showed that a pressure of 690 MPa for 5 minutes had the greatest effect

on polyphenol oxidase activity (Palou et al., 2000). Since the High Pressure Press available to us

in the pilot plant only reaches a maximum pressure of 400 MPa, we had to run our product at a

lower pressure for a longer time.

Under Dr. San Martin’s supervision, we chose to process our soup at 300 MPa for 30

minutes, hoping to emulate the process done in the research experiment as close as possible. Due

to complications and malfunctioning of the High Pressure Press during the trial run, we were not

able to reach 300 MPa. During three different trials our pressure ranged from 210 MPa to 270

MPa. We adjusted our processing time accordingly and continued processing. Upon completion

of our pilot plant trial, we obtained promising results. We found that there was no browning in

the avocado and no off flavors or odors from the cucumber or avocado. Comparing the visual

and analytical testing data from the HPP trial with the two thermal processes, we found that the

HPP resulted in a more visually pleasing, higher quality product.

Not only did the High Pressure Press result in a superior product during our pilot plant

trials, but other high quality products on the market are being processed with High Pressure as

well. HPP was essentially discovered in the early 1900’s but it was not until the 1990’s that it

started being used commercially (Fresher Under Pressure, n.d.). Since then, HPP technology has

grown and been very successful. One company that has been doing particularly well is

Fresherized Foods. Currently, Fresherized Foods is commercially producing a line called

Wholly which includes salsa, bean dip, guacamole, and a 100% chunky avocado dip. Because

these products are being processed with High Pressure and are refrigerated after, they have no

preservatives and a much higher quality than similar products being thermally processed. In fact,

it is not possible to commercially process guacamole or avocados for retail without using HPP.

There are currently several ‘guacamole dips’, such as Deans, Mission, and Ortega, on the market

which are made with avocado powder or contain less than 2% real avocado. These products taste

nowhere near the same as homemade guacamole and have very complex labels that are scaring

the rising population of health conscious consumers away. That being said, our soup cannot be

commercially processed any other way to achieve the quality necessary for a premium soup due

to it containing real avocados.

Furthermore, Bolthouse recently launched a line of Cold-Pressed juice which is processed

High Pressure. This further justifies the use of High Pressure on our product since we are


labeling under the Bolthouse brand. Fresher Under Pressure is currently the copacker for

Bolthouse’s cold-pressed juices. Fresher Under Pressure successfully processes a wide variety of

products, including soups and guacamole. Since our product is essentially a cross between a soup

and guacamole, HPP is the best option.

Process Design

This section of the report covers how we would scale up our HPP pilot plant trial and

manufacture this product in industry. A flow diagram of the process can be found in Figure 2 in

this section of the report. This product is safe for consumption because it has a pH below 4.6, it’s

processed with High Pressure, and it’s stored at refrigerated temperatures. Because the pH is

below 4.6 and the product is refrigerated, Clostridium botulinum is not a concern because it

cannot grow under these conditions. The microbial concerns for safety of this product are

Escherichia coli, Listeria monocytogenes, and Salmonella because they are able to withstand

acidic conditions. Yeasts and molds are also acid tolerant so they are a microbial concern for this

product in terms of spoilage and quality. Research shows that vegetative cells and spores are

quickly inactivated at pressure of 500 MPa and above (Hocking et al., 2006).

Receiving and Storing Ingredients

Because our product contains a lot of fresh produce, the most important steps in our

process are the receiving and storage of the ingredients, specifically the produce. It is crucial to

review the Certificates of Analysis for each ingredient and confirm that they match the

specification sheets. Because ripeness of produce can vary greatly, we want to ensure that what

we receive is consistent as possible. This will be controlled by acquiring reliable suppliers and

proper storage of the produce upon receiving. For specific detail on receiving and storing

ingredients, refer back to Section II, Tables 4 and 5 of the report. We have chosen to use frozen

melon chunks that will be thawed before processing instead of starting with whole melons. This

will save time during processing and reduce variability of ripeness in the melons.


Batching

There will be separate operations for batching the dry ingredients, the wet ingredients,

and the produce. Refer back to Section II of the report for specific details on batching.

Blending

After the dry ingredients, wet ingredients, and produce have been prepared for

processing; they will all be dumped into a blender and blended for 20 minutes to ensure a

uniform consistency throughout the product.

Packaging and Checking Weight

HPP is a unique technology that requires the product to be in a completely sealed

package before processing. Therefore, directly after blending, the product will be filled into a

PET package and vacuumed sealed with a LDPE film. After packing we will make sure the net

weight is within an acceptable range of our target weight, 480 grams. To be in compliance with

the FDA, the net weight can deviate no more than 0.5% under the labeled weight (Coleman et

al., 2005). We also want to make sure that we are not going over our labeled net weight.

Delivering more than necessary is considered a loss of product, which in turn is a loss of profit.

High Pressure Processing

Acquiring HPP equipment is very costly. Rather than purchasing all of the equipment

necessary for HPP, we would partner with a copacker that specializes in HPP. We would copack

with High Pressure Processing Food Services located in Wilmington, CA. Because our avocado

source is also in California, this would allow the avocados to be picked at the peak of their

ripeness since they would have a shorter distance to travel. HPP Food Services is in partnership

with Avure Technologies. Specifically, the Avure HPP model we would be utilizing to

manufacture our soup is the AV-60. This model is capable of reaching a throughput of

63,000,000 pounds per year and is able to accommodate a wide variety of foods. This product

will be processed at 690 MPa for 5 minutes. The enzyme responsible for browning in avocados,

polyphenoloxidase, will only be partially inactivated under these processing parameters

(Castellari et al., 1997). The amount of pressure needed to completely inactivate

polyphenoloxidase is not logical to use for manufacturing this product because higher pressures


are more costly and wear down equipment faster. However, storing the product under

refrigeration will slow the enzyme activity even further.

Post-Processing

After High Pressure Processing, the secondary PET lid will be put on the package. The

package will then be labeled and sent through a metal detector. After the product has been

successfully processed and packaged, it will head into storage and distribution. This product will

be stored and distributed at refrigerated temperatures.


Figure 2. Product Process Flow Diagram

KEY: -Quality Control Point -Critical Control Point

Dry

Ingredients Wet

Ingredients

Produce

(1a) Receive

Ingredients

(3f) Halve

avocados

(2a) Receive

Ingredients

(3g)

Remove

skin and pit

manually *CCP: Pitting

avocado

(3c) Wash

cucumbers

(3d)

Peeling

(3e) Dicing

(1”)

(3b) Thaw

melons

(3a) Receive Ingredients

2b) Lemon

juice conc.

(2c)

Diluting

(1b)

Sieving

(1c) Dry

Blending

(4) Blending 20 minutes

*CCP: monitoring pH

(2d) Yogurt

& Veg.

Stock

(5) Filling

Package

(6) Vacuum

Seal

(9) Lid

Insert

(12) Storage &

Distribution

(8) Check

Weigher

(10)

Labeling

(7) HPP 690 MPa,

5 minutes

pHpH

(11) Metal

Detector

pH


Table 7. Equipment

Type of Equipment Company & Model # Capacity/Maximum Quantity

Penetrometer Wagner Instruments, FT

40 (FT044) 40lbfx 0.5lbf 20kgfx 200gf

5

Hopper A-One Manufacturing,

V-Mag Cart 750 lbs. 4

Mixing Tank PulsairSystems,Inc,IBC

Tote Mixer 1000gallons 2

Dumper FPEC,HyLiftDumper 3000lbs. 1 Dry Blender Ross Blenders, Double

Cone Blender 15 cu. ft. 1

Sieves RussellFinex,FinexSieve 60 mesh, 250

microns (pepper,

mint & onion)

3

RussellFinex,FinexSieve 30 mesh, 595

microns (salt) 1

Blender FPEC, V-Mixer 250-12,000lbs. 1 Slicer for Avocado FamMachines, FAM

3MGD 15 kg/hr 1

Dicer for

Cucumber Urschel,

ETranSlicerCutter Product up to 4"

(101.6 mm) in

diameter

1

HPP Avure, AV-60 1845 kg/hr for a 6

minute hold time 1

Peristaltic Pump Watson-Marlow,

Hygienic pump with

840pumphead

35gpm(8,140 l/hour) 5

Produce Washer Key Technology, Flume Washer

7000kg/hr 2

Packaging Filler Osgood Cup Filler, Inline 3600 E-L

80-120cups/minute 1

Package Sealer Osgood Cup Filler, Inline 3600 E-L

80-120cups/minute 1

Lid Inserter Osgood Cup Filler, Inline 3600 E-L

80-120cups/minute 1

Check Weigher Alpha, CW-10 12lbs, 350 units/min 1 Labeler Krones,AutocolAPS3 48,000 containers/hr 1 Metal Detector Lomo,[Equation]Metal

Detector Conveyer Max weight: 25 kg Belt speed:up to 90

m/min

1


Process Quality Control

The key quality attributes of this product are color, pH, viscosity, and the solids content.

In order to achieve the highest quality possible, we have established quality control points

throughout the process related to these key attributes. Details on the equipment used and critical

control limits can be found in Table 8 of this section.

Receiving Ingredients

This is a critical quality control point because our product cannot be successfully

processed unless the ingredients are within specification. The quality of the incoming ingredients

will be controlled by reviewing the Certificates of Analysis for each product and making sure

that they match the specification sheets.

Ingredient Storage

Ingredient storage is especially important in this process because we are handling a large

quantity of fresh produce. Monitoring the storage temperatures will control the quality of the

produce. Further information on ingredient storage can be found in Table 5 of Section II.

Batching

Peeling and pitting the avocado during batching is a quality control point. This step

would be controlled by visual inspection to ensure that there is no skin or pits of the avocados

sent further into processing. Thawing the melons is another quality control point because we do

not want to compromise the structure or quality of the melons during this step. Monitoring the

temperature that the melons are thawed at will control this.

Pre-Processing

All of the quality attributes in this section would be measured after blending, just before

packaging. The color of the soup is the most important attribute because it is one of the factors

that consumers will use to decide whether or not to purchase the product. In addition, the soup

has a very specific, vibrant color so we want to ensure that the color is with specification each

time we process a batch. The pH of our product is a quality control point as well as a critical

control point. One attribute of this soup is its mild acidity, which comes from the lemon juice


and the yogurt. The pH is also what makes our product safe because it is below 4.6. More about

this critical control point can be read in the HACCP section of this report. The viscosity is a big

contributor to the profile of our soup. Because of this, we must ensure that the viscosity is within

our specifications.

Sealing the package is another quality control point that needs to be checked before High

Pressure Processing. Vacuum sealing will help ensure no leakage or loss of product and as little

oxygen in the package as possible.

HPP

Processing the product with High Pressure is a quality control point rather than a critical

control point. We know our product will be safe because the pH is below 4.6 and the product is

being refrigerated immediately after processing. This is a quality control point because we want

to ensure that we are hitting our target processing parameters in order to inactivate as much of

the polyphenol oxidase enzymes from the avocado as possible to prevent browning.

Additionally, we want to destroy as much yeasts and molds as possible during HPP to prevent

spoilage since these microorganisms can withstand high acid environments.

Post-Processing

The headspace of the package is also a quality control point because it contributes to the

shelf life of the product. We want to ensure that the environment of the package is ideal for

upholding the key quality attributes of the soup. Additionally, the quality of the finished product

would be analyzed. More information on this can be found in Section 4 of this report. Checking

the net weight of the product is a crucial quality control point because we want to ensure that we

are delivering the amount of product to the consumer that we say we are on the label. Also, the

FDA only tolerates a -0.5% deviation from the labeled net weight so we must check the net

weight constantly to ensure we are in compliance with the law (Coleman et al., 2005).


Table 8. Details on Quality Control Points

Process

Step

Measurement Equipment/

Method

Lower & Upper

Control Limits

Frequency Corrective

Action(s)

Receive

Ingredients

Review C.O.A’s and confirm with the specification sheets

More details in Section II Table 4

Return to

supplier if not

correct

Ingredient

Storage

Temperature Thermometer More details for

each ingredient in

Section II Table

4

Every 3

hours

Salvage as

much product

as possible or

dispose of

properly

Peeling &

Pitting

Avocado

Visual Inspection No skin or pit

acceptable

Constantly

Remove

excess skin/pit

Thawing

Melons

Temperature Thermometer 10-13°C Every 3

hours

Salvage as

much product

as possible or

dispose of

properly

Blending Time Timer 20-22 minutes Constantly Rework

product

Post

Blending

Color Handheld

HunterLabCo

lorimeter

L: 60-65 ± 2.8

a: 25-30 ± 0.5

b: 3.0-4.0 ± 0.8

Once per

batch, in

triplicates

Rework

product or

dispose of

properly

pH Handheld

Thermo

Scientific pH

meter

4.2 ± 0.05

Viscosity Handheld

Brookfield

Viscometer

830 cP ± 50

Total Solids Forced Draft

Oven

*To be

determined in

future testing

Packaging Seal Strength Labthink

XLW

AutoTensile

Tester

.540 N/mm ±

.010 N/mm

Once per

hour

Rework

product if

possible

Headspace Mocon

Headspace

4% O2 ± 1% Once per

hour


Gas Analyzer

HGA-03

HPP

Time and

Pressure

HPP

computer

monitor

(PLC)

690 MPa for 5

min.

± 23 MPa,

± 10 seconds

Monitor

pressure

and time

Rework

product if

possible

Checking

Weight

Weight Scale 480 g (will

accept up to 0.5%

under)

Constantly Rework

product


Packaging

We believe that our latest and greatest Chilled Avocado-Cucumber Soup with melon

warrants a package that will catch the consumer’s eye. After reading Mintel reports and

consumer reviews of current Campbell products, a clear package is critical; many consumers

have turned away from soups due to their notorious bad quality. We are also marketing this as

an ultra-premium soup, therefore by packaging our soup in a clear package we are inviting the

customer to explore and visually see the constituents of the soup prior to purchasing.

PRIMARY

Our initial plan was to go with a package that was similar to that of The Chia Company’s,

Chia Pod Oats or Chia Pod. It aligned with what we were looking for: catchy, convenient, clear.

After consulting with Dr. San Martin, she did not think we would be able to do use a high-

pressure process with this type of a package. Dr. San Martin told us to not rely solely on her

opinion, so we are currently awaiting a reply from the HPP experts at Avure Technologies as to

whether or not the packaging, below, is plausible.

Figure 3: Chia Pod Packaging, The Chia Co.

Until we hear back from Avure, we are changing our packaging to something that we

know can be high pressure processed because it is already being processed in that manner.

Below, is a guacamole called Pico de Guaco and we think that although this packaging does not

look as modern or fresh as The Chia Company’s, it still allows the consumer to see what the

soup looks like and that is the most important aspect. In addition, it is the proper size.


Figure 4. Pico de Guaco, East Coast Fresh

The base of the above container is composed of polyethylene terephthalate (PET). PET’s

high impact strength is ideal for distribution and it is also a good gas and water vapor barrier

(Mauer, 2015). In addition, PET is a clear plastic which will allow the consumer to see our soup,

which is an extremely important quality for our package to have. The cup is heat-sealed with a

low-density polyethylene (LDPE). There are several advantages to LDPE. This plastic is great

because it has the lowest softening point, meaning that it will melt and create a seal (at

temperatures between 223oF-234oF) while the remainder of the package will remain intact

(Mauer, 2015). Additionally, it is a good moisture barrier and is clear, which will allow the

customer to see the quality soup they are receiving. The next aspect of the package is the lid.

This lid is once again LDPE. LDPE is ideal for snap-on lids because it is flexible. (Mauer, 2015)

The package itself is important, but equally important is how we prepare that package

before filling it with our cold soup. We intend to use hydrogen peroxide (H2O2) in spray form

with concentrations up to 30% and a contact time of up to 15 seconds (Ansari, 2003). After this

contact time is reached, the package will go through hot air to evaporate the remaining hydrogen

peroxide (Ansari, 2003). Todd Putnam, CCO of Bolthouse Farms, confirmed hydrogen peroxide

as the method Bolthouse uses to sanitize their packages. The main consideration when using

H2O2 is that the final product must have less the 0.5ppm H2O2. To ensure this concentration is

met, the Ferric Thiocyanate Method can be used. This method involves CHEMetrics CHEMets

and Vacu-vials, which express results in ppm (mg/L) H2O2 (“Hydrogen Peroxide”).

Beyond ensuring the proper concentration of hydrogen peroxide, we need to ensure that

the LDPE heat seal is properly adhered. To do so, quality technicians will obtain three packages

off the production line to run a seal-strength test in triplicate. We will also use an Auto Tensile


Tester, which measures the physical force and tensile strength of plastic films (“Tensile

Strength”).

SECONDARY

The secondary package for our chilled soup will be a cardboard carrier that have a nine-

compartment divider that can carry forty soup bowls at one time.

TERTIARY

The secondary cardboard boxes will then be palletized and wrapped in Polyvinylidene

Chloride (PVdC) to secure the structure. Then it will be moved to either a refrigerated

distribution truck or to refrigerated storage.

Figure 5. Palletization Illustration


Sanitation

It is critical to sanitation that our processing facility follows Title 21, Part 110 of the

Code of Federal Regulations, which lists the current Good Manufacturing Practices. In order to

ensure that our product is safe-to-consume we need to make sure that all factory workers are

following good hygiene practices (bathing, washing hands) and that they are wearing hair nets,

gloves, clean coats, and sanitized shoes at all times. In addition, the processing facility needs to

be designed with sanitation in mind. Things such as methods to hang up brooms, water/chemical

lines, draining systems, proper hose storage, and more must all be considered. The environment

outside of the facility should promote sanitation, as well. Surrounding the facility with concrete

instead of something like mulch and plants, which harvest microorganisms and bugs.

An advantageous aspect of our process is that it is high pressure processed. That means

that our process uses only water at extremely high pressures (6,000 bar/87,000 psi) to inactivate

microorganisms such as Listeria, Salmonella, and Escherichia coli (“Why High Pressure.”). The

main consideration with this method is that the water inside the vessel is potable. This is

important because consumers will come into contact and eat directly from the processing

container.


Preliminary Hazard Analysis Critical Control Points

This HACCP Plan has been created referencing the United States Department of

Agriculture’s Guidebook for the Preparation of HACCP Plans (USDA, 1997). There are

prerequisites that must be addressed before creating a HACCP Plan. Good Agricultural Practices,

Good Manufacturing Practices, Standard Operating Procedures, and Sanitation Standard

Operating Procedures must be followed. Any raw ingredients and final product must be traceable

and have lot codes for product that may need to be recalled. In addition, the storage and usage of

chemicals used in the facility must be documented and regulated with Material Safety Data

Sheets.

The HACCP Team

The most important step in making a HACCP plan is first assembling a reliable HACCP

team that will successfully prevent and minimize hazards that may occur during processing. Our

HACCP team would consist of a team leader who has been HACCP trained, sanitation manager,

microbiologist, process engineer, production manager, and a quality assurance manager.

Description of Product & Intended Use

Our product is a chilled soup. The soup is ready-to-eat and requires no further preparation

upon purchasing. The type of package used is a PET bowl that is vacuumed sealed with a LDPE

seal, closed with a PET lid. The shelf life of this product is 3 months. This chilled soup will be

sold in retail grocery stores in the refrigerated section and should be distributed and stored at

refrigerated temperatures as well. It’s also important that the labeling of this product includes the

handling instructions “Keep Refrigerated.


Table 9. Processing Hazards

Critical

Control

Points

Potential

Hazard

Hazard

Type

Critical Limits Preventative

Action(s)

Corrective

Action(s)

Receive

raw

ingredients

Pesticide/fertilize

r residues, foreign

materials,

bacteria (avocado

& cucumber)

C, P, B FDA Defect

Action Levels,

TPC: 100,000/ g,

Enterobacteriace

ae <500/g,

E. coli <10/g,

Yeast and

Molds: <5000/g,

Salmonella:

Neg/25g,

Staphylococcus:

Neg/25g,

Listeria

monocytogenes:

Neg/25g

Have reliable

suppliers,

review

C.O.A’s,

have strict

GAP’s and

GMP’s

Refuse to

accept, send

back to

supplier

Bacteria (frozen

melon chunks)

P, B TPC: 100,000/ g,

Enterobacteriace

ae <500/g,

E. coli <10/g,

Yeast and

Molds: <5000/g,

Salmonella:

Neg/25g,

Staphylococcus:

Neg/25g,

Listeria

monocytogenes:

Neg/25g

Have reliable

suppliers,

review

C.O.A’s,

have strict

GMP’s

Refuse to

accept, send

back to

supplier

Bacteria, yeast &

molds (Yogurt)

B Coliform: <10/g

Yeast and

Molds: <50/g

Have reliable

suppliers,

review

C.O.A’s,

have strict

GMP’s

Refuse to

accept, send

back to

supplier

Bacteria

(vegetable stock)

B E. coli <10/g,

Yeast and

Molds: <5000/g,

Salmonella:

Neg/25g,

Have reliable

suppliers,

review

C.O.A’s,

have strict

Refuse to

accept, send

back to

supplier


Staphylococcus:

Neg/25g,

Listeria

monocytogenes:

Neg/25g

GMP’s

Lemon juice

concentrate

B TPC: 2000

cfu/ml max

Yeast: 1000

cfu/ml max

Mold: 50 cfu/ml,

max

Have reliable

suppliers,

review

C.O.A’s,

have strict

GMP’s

Refuse to

accept, send

back to

supplier

Foreign

materials,

bacteria (sea salt)

P, B Salmonella:

negative

Listeria: negative

Have reliable

suppliers,

review

C.O.A’s,

have strict

GMP’s

Refuse to

accept, send

back to

supplier

Foreign

materials,

bacteria (onion

powder, mint

powder, ground

pepper)

P, B Aerobic Plate

count 25,000/g

max

Yeast & Mold:

400/g max

Coliforms: 100/g

max

E. Coli: negative

in 11g

Salmonella:

negative in 25g

Have reliable

suppliers,

review

C.O.A’s,

have strict

GMP’s

Refuse to

accept, send

back to

supplier

De-pitting

avocado

The pit of the

avocado is a

choking hazard

P Zero tolerance Thorough

visual

inspection

Remove any

excess pit

pH The pH must be

below 4.6 to be

considered a high

acid food &

prevent certain

microorganisms

from growing

B 4.2 ± 0.05 Make sure

the lemon

juice

concentrate is

being

correctly

diluted,

monitor pH

Rework

product

Metal

Detector

Metal P Zero tolerance

for metal

Have strict

GMP’s &

SOP/SSOP’s

Dispose of

product

properly


IV. Finished Product Final Quality Standards & Specifications

The final product should meet the standards as shown in Table 8. The standards are built

based on freshly made product (not processed) with upper and lower limitation. In this way, the

quality of finished products can be assured to have the same quality as the freshly made one.

Table 10. Final product standards

Test Acceptable Ranges

pH 4.20 ± 0.05

Color

(by colorimeter)

a: -3.56 ± 0.80

b: 26.64 ± 2.00

L: 65.42 ± 2.00

Viscosity (cP)

(by Brookfield viscometer)

843.33 ± 50

Total Solids

(by forced draft oven)

To be determined*

*Note: After conversing with Dr. Ferruzzi and Amber Furrer, it was decided that we needed to run Total

Solids to make sure we are consistent in what we give to our consumers. However, we did not have time

to conduct the proper testing, but if we were moving forward with this product, we would run Total

Solids.

Finished Product Specifications

Product Name: Bolthouse Chilled Avocado-Cucumber Soup with Melon

Identification: The Bolthouse Chilled Avocado-Cucumber Soup with Melon is 100% natural

and contains no additives

Style Product must be refrigerated through all phases of storage and shipping

Color Light green color

Texture Creamy and with small particulates

Defects All the vegetable and/or fruit ingredients shall be ripe at proper level. No

vegetable and/or fruit skin and/or seeds are allowed in the product

Character The soup shall be light green color, not excessively watery or and not

contain large chunks or segment


Flavor/Odor Free from any Off-Flavors and Off-Odors of any kind

Chemical Free of any pesticides

Microbiological Free of harmful microbes

Escherichia coli <10 g

Yeast & Molds <10 g

Salmonella Negative

Listeria monocytogenes Negative

Metal Detector All products must pass through a properly operating metal detector.

Label Codes must be printed on each box and shipping documents

Storage/Shipping Keep temperature at 4°C

Documentation COA, specification

Shelf Life 3 months

Ingredients Yogurt, frozen melon, cucumber, vegetable stock base, avocados, lemon

juice concentrate, sea salt, onion powder, pepper (ground), mint leaves

(powder), and water


Organoleptic Analysis

Organoleptic or sensory analysis will be conducted to determine sensory properties, shelf

life and product’s attribute. Two different types of sensory analysis – descriptive analysis and

consumer acceptance testing will be used. Unstructured scale rating method will be used for

descriptive analysis, which defines the sensory profile of the product and tracking sensory

changes over time. We will measure consumer acceptance by testing 50 panelists who will rate

our product using a 9-point hedonic scale. Feedback from panelists will be collected then

analyzed. The key sensory attributes of this product are taste, appearance, aroma, flavor and

texture.

Unstructured scale rating – Ten well-trained panelists will complete an unstructured scale rating.

All possible sensory aspects of the product are detected and collected from panelists, then the

intensity of each sensory aspects are rated on questionnaire sheet. This test shall be done with the

shelf life to track changes in sensory aspects (see Shelf Life section). The possible sensory

aspects are listed in Table 11.

Table 11. Sensory Attributes and Aspects

Taste Appearance Aroma Flavor Texture

Saltiness Color Cucumber Cucumber Creamy

Sourness Viscosity Melon Melon Particulate

Sweetness Consistency Avocado Avocado Sedimentation

Astringency Yogurt Yogurt

Bitterness Mint Mint

Pepper Pepper

Onion Onion

Lemon Lemon

Hedonic scale – 50 panelists are need for this test. The samples of the product are presented to

panelists and they will rate how much they like or dislike for each sensory attributes.


Nutritional Labeling

Figure 6. Nutrition Label

INGREDIENTS: YOGURT (CULTURED GRADE A NON FAT MILK, PECTIN),

HONEYDEW MELON, SEEDLESS CUCUMBERS, VEGETABLE STOCK, HASS

AVOCADO, LEMON JUICE (FROM CONCENTRATE), SEA SALT, ONION POWDER,

BLACK PEPPER, DEHYDRATED MINT

CONTAINS: MILK


Nutritional Analysis Tests

Table 12. Final Product Nutritional Analysis

Measurement Test/Method Description

Calories N/A Calculated from nutrient composition

Calories from fat N/A Calculated from Total fat

Total fat AOAC Method 996.06 Gas Chromatography

Saturated fat AOAC Method 996.06 Gas Chromatography

Polyunsaturated fat AOAC Method 996.06 Gas Chromatography

Monounsaturated fat AOAC Method 996.06 Gas Chromatography

Tans fat AOAC Method 996.06 Gas Chromatography

Cholesterol AOAC Method 976.26 Gas Chromatography

Sodium AOAC Method 996.16 Flame Spectrophotometric

Total Carbohydrates N/A Calculated by total calorie content

minus calorie from all other nutrients

Dietary fiber AOAC Method 985.29 Enzymatic-Gravimetric method

Sugars AOAC Method 44.5.06 Polarimetric method

Protein AOAC Method 920.152 Kjeldahl method

Vitamin A AOAC Method 2001.13 Liquid Chromatography

Vitamin C AOAC Method 967.22 Microfluorometric method

Calcium AOAC Method 929.07 Double precipitation

Iron AOAC Method 944.02 Spetrophotometric method

Vitamin D AOAC Method 980.26 Liquid Chromatography


Shelf Life

The shelf life of the Avocado-Cucumber Soup with Melon is determined by its sensory

profiles, like color, flavor, and texture. The expected shelf life is 3 months. After this period of

time, the sensory attributes of the soup will be lost and the product will not meet the consumer’s

expectation. The causes for the end of shelf life are color change due to enzyme oxidation of

avocado, the flavor change due to milk fat oxidation in yogurt and spoilage of ingredients, as

well as the texture change because of sedimentation.

Methods

To verify the expected shelf life, real time testing will be conducted. Our product does

not need accelerated shelf life testing because the shelf life is only three months. With that being

said, we would begin a real time test and after one month of testing, we would launch our

product into the market. If anything were to go wrong in the remaining two months of testing,

we would pull the product from the shelves. For the real time test, the samples will be stored at

4°C with light exposure at 75-85 foot-candles (fc) of illuminance and monitored over time until

it fails to meet the specifications (Magari, 2003). The range of 75-85 fc of illuminance is chosen

because it is the suggested amount of light for a supermarket produce section. The temperature,

light, and gravity are key attributes that cause the product to deteriorate. All the test samples will

be obtained as the primary package contained the processed soup. All the samples should be

collected at the same time and same batch to increase accuracy of results. Tests should be done

as soon as possible when the sample is opened. Opened sample shall be disposed after tests are

done.

Real time – 45 samples will be randomly picked from the same batch and stored at 4°C with light

exposure at 75-85 fc of illuminance until they fails to meet the specification. The expected

duration of this test shall be the same as the expected shelf life (3 months). Every week three

sample will be opened and tests will be conducted for each parameter listed in Table 13. The

breaking points are browning color, sensory fail to meet consumer expectation, sedimentation or

separation.


Table 13. Parameters and Test

Parameter Test/Method

Color Visual check and colorimeter

Sensory Sensory analysis-unstructued scale rating (see Organoletptic

Analysis)

Texture Visual check for sedimentation

pH pH meter

Viscosity Brookfield viscometer

Microbiological Total Plate Count

Gravity Visual check for sedimentation or separation


Regulations & Requirements

The Food Allergen Labeling and Consumer Protection Act of 2004 (Public Law 108-282,

Title II) mandates that the labels of foods containing major food allergens (milk, eggs, fish,

crustacean shellfish, peanuts, tree nuts, wheat and soy) declare the allergen in plain language.

This product contains a milk allergen, and thus “Contains milk,” will be stated directly below the

ingredients section of the information panel.

Final Cost Analysis Please refer to the cost tables in Appendix D for further detail. Our most expensive

ingredient is the lemon juice concentrate and secondly, the low-fat, plain yogurt. If we can get

these costs down we could greatly increase our margins. In addition, our product is extremely

agricultural. The implication is that if there is a blight that affects one of our ingredients, we may

have to reformulate or take a lesser profit.


V. Future Directions

Future Product Improvements & Next Steps

The future of Project C.S.I. is a bright one. Based on Mintel Reports, we know that cold

soup is an up and coming trend and will increase in sales into 2018 (Mintel, 2014). Consumers

are looking for a healthy, clean-labeled product to grab on the go, and we believe cold soup is the

answer. With that being said, we would like to see our product idea undergo further research

(e.g. Total Solids Content) and to develop into various other flavors. These flavors could be

anywhere from a gazpacho that is available year-round to more seasonal soups. In the fall,

Autumn Squash, Spring-Spring Pea, and lots of flavors for the hot Summer- Chilled Peach,

Sweet Corn & Cashew, or Sour Cherry with Fennel (Cold Soups). The possibilities are endless!

Perhaps we could even ask our ever-returning customers for their recipe ideas, similar to Lay’s.

In addition to other flavors, customization is also very popular in the market today.

Mintel Reports are showing that consumers would like toppings on their soup (Mintel, 2013).

With the idea of toppings in mind, perhaps we could change our packaging to include a side

compartment (similar in style to the Chobani Flips). For example, our Chilled Avocado-

Cucumber with Melon could be paired with toasted pine nuts. A gazpacho could have toppings

such as feta cheese, olives, or yogurt (Classic Gazpacho). These toppings will make consumers

feel like they are getting more bang for their buck in addition to a restaurant-quality product that

is conveniently packaged and ready to go.

We believe that our next steps need to include education for the consumer. A cold soup

such as ours is non-existent in the American marketplace and consumers do not know if they

want to spend money to try something they have never had before. Perhaps, we can do free

samples in markets such as the Midwest that might be more tentative to try our product in

comparison to the coasts. Within that step of education, we need to let them know that our

Avocado-Cucumber Soup with Melon exists! In order to do this, we will need marketing. Signs

that say “New!” in the grocery stores near the product would be effective and perhaps TV/radio

commercials from Bolthouse Farms.


VI. Appendices

Appendix A: Acknowledgements

Project CSI would not have been possible without the help from several people along the way.

We would like to give a special thank you to:

Dr. Mario Ferruzzi

Ms. Amber Furrer

Dr. Lisa Mauer

Dr. Haley Oliver

Ms. Susan Hammons

Mr. Matthew Allan

Mr. Steve Smith

Mr. Mathias Bohn

Mr. Todd Putnam, CCO-Bolthouse Farms

Mr. Casey Young, R&D, Campbell Soup Company

Ms. Menexia Tsoubeli, R&D, Bolthouse Farms

All guest lecturers

All suppliers

Without these people and the support of the Purdue Food Science Department, this project would

not be possible. Thank you for giving us an opportunity to show what we have learned during

our tenure at Purdue.


Appendix B: References

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0

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toppings-bar/

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S., Van Loey, A. and Hendrickx, M. (2011), Effect of Pilot-Scale Aseptic Processing on

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method&es_sm=119&source=lnms&tbm=isch&sa=X&ei=-

90lVbrPJcSHsAXBx4DYDg&ved=0CAkQ_AUoAw&biw=831&bih=870&dpr=0.9#tbm

=isch&q=palletizing&imgdii=okdIs_-Tt6KjxM:;okdIs_-

Tt6KjxM:;ZokT4qhOxGMYRM:&imgrc=okdIs_-T

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http://www.avure-hpp-foods.com/why-hpp


Appendix C: Ingredient Specification Sheets


Appendix D: Cost Analysis

Ingredient Cost

Ingredient Percentage/100g Percentage

/ Package

(240g)

Percentage/

Package

(kg)

Cost/

Package

Yogurt-Plain, Non-fat 29.60 71.04 0.07104 $0.125

Honeydew Melon 23.50 56.40 0.05640 $0.093

Cucumbers-Seedless 15.00 36.00 0.03600 $0.045

Vegetable Stock Base 15.00 36.00 0.03600 $0.010

Hass Avocado 13.30 31.92 0.03192 $0.046

Lemon Juice Concentrate 2.60 6.24 0.00624 $0.175

Pure Ocean Atlantic Sea Salt 0.40 0.96 0.00096 $0.002

Onion Powder 0.30 0.72 0.00072 $0.004

Peppercorn-Ground 0.20 0.48 0.00048 $0.007

Mint Leaves Powder 0.10 0.24 0.00024 $0.002

Water 0.00 0.00 0.00000 0.000

Total Ingredient Cost/Package $0.509

Unit Cost

Component Cost ($)/ Package Cost ($)/ Batch

Product 0.509 2122.70

Package 0.030 124.98

Total Product + Package 0.539 2247.68

Cost Structure

Cost Structure- High Margin, Low Volume Product

Component Composition (%) Cost ($)/

Package

Cost ($)/ Batch

Production Cost 38% 0.19 $854.12

Net Profit 33% 0.17 $741.73

Marketing & Admin. 16% 0.08 $359.63

Distribution 8% 0.04 $179.81

Other 5% 0.05 $112.38

Final Product Cost 100% 0.53 $2,247.68


Production Costs Component Composition (%) Cost ($)/ Package Cost ($)/ Batch

Raw & Packaging

Materials

69.00 1.087 4528.442

Human Resources 14.00 0.221 918.814

Other Expenses 9.00 0.142 590.666

Depreciation 6.00 0.095 393.778

Energy 2.00 0.032 131.259

Product Production

Costs

100.00 1.575 6562.959

Project CSI

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