A plant that does not know its real weight loss or its cost per kilo does not have a flavour problem: it has a control problem. That is always where the work starts.
Redesigning the formula to produce cheaper without the customer noticing: lean-fat-water ratio, functional proteins, phosphate system and thermal yield.
What has to change in formula, process, packaging and labelling for the product to enter the destination market: European Union, United States, Gulf states, Mercosur or the Andean Community.
Bringing formula and plant in line with halal or kosher requirements: replacing critical ingredients, line segregation, traceability and preparation for the certifying body’s audit.
Determining real shelf life by trial — microbiological, physicochemical and sensory — instead of copying a competitor’s date.
Cutting salt, nitrite, phosphates and allergens without losing microbiological safety or texture. It is the requirement advancing fastest in every market’s regulation.
Sizing a poultry, pig or cattle operation: stock numbers, housing, feeding plan, health programme, and the figure almost nobody calculates properly — the feed conversion ratio.
Design of your own feed mill: grinding, mixing, pelleting or extrusion, and the dosing system that makes every tonne come out like the last one.
Calculating the ration that meets the nutrient requirement for the species and stage at the lowest possible cost with the raw materials available in your region — not the ones in the textbook.
Turning into saleable product what you currently pay to dispose of: meat and bone meal, blood meal, tallow and fats. Sizing, equipment and route to market.
Formulation and process for extruded dog and cat kibble: nutrient profile, extrusion parameters, palatability and coating.
Mayonnaise, ketchup, mustard, hot sauces and dressings: stable emulsion, safe pH, target viscosity and shelf life without a cold chain.
Setting up or fixing a precooked corn flour, bakery blend or dry pasta line: gelatinisation, flaking, drying curve and particle size.
Full process review with the numbers in hand: yield per batch, real weight loss, cost per kilo, points of loss.
From concept to production: target formulation and its translation into an industrial batch, with the salt, phosphate, ice and fat adjustments the jump in scale demands.
What equipment the target capacity needs, in what order to buy it, and the real throughput of the whole line rather than the number on the manufacturer’s sheet. Includes used equipment appraisal.
HACCP plan with real critical limits, not copied from a template, and assembly of the dossier for whichever registration the country requires.
Nutrition panel calculation, ingredient list in the correct order, allergens, and the claims the destination country allows or forbids.
Independent technical opinion when there is a rejected batch, a dispute with a supplier, or a claim to argue with an insurer.
Training for the people who actually handle the batter: temperature control, order of addition in the cutter, reading defects, and why each step sits where it sits.
A specific question with a specific answer: why the emulsion broke, what dosage applies, why pH will not drop, whether an ingredient is legal in a given country.
We produce under your brand so you can have a catalogue without building a plant: you bring the brand and the market, we bring production and the technical sheet.
Starter cultures, natural and collagen casings, curing salts, phosphates, spice blends and noble mould. What is hard to source in Venezuela and without which there are no cured products.
For the producer who knows how to make the product but cannot fund a humidity-controlled chamber: we rent the full cycle with recorded weight loss.
Developing a supermarket or restaurant chain’s own line: product to their specification, at their target price and under their label.
Plant workshop for butchers, charcutiers and hotel kitchens: fresh, scalded and cured, hands in the batter.
We answer in English, Spanish, Portuguese, French, Italian and Arabic. If your question is technical and specific, so is the answer.