Smart Functionals
Functional systems and process windows for stable texture, moisture and yield across variable raw materials
Our approach
We design functional systems that lock in texture and water binding under industrial conditions. Formulations are tied to defined process windows and validated on your lines. Each solution maps dosage, mixing energy, temperature profile and hold times, then is standardised into SOPs and specs.
Outcomes
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Stable emulsions and fat distribution
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Usable variability in PSE pork and DFD beef
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Lower cooking and smoking losses
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Consistent bite, colour and slice integrity
Operational framework
Formulation design
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Define functional targets for texture, moisture and binding
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Specify blend families with ALMI codes and usage ranges
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Map interactions with salt, phosphates and proteins
Variable raw materials
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Tolerance windows for PSE pork and DFD beef
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Adjust pH, ionic strength and myofibrillar extraction rates
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Ensure consistent binding, colour and yield in all conditions
Quality & specification
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Define test points for texture, moisture, yield and colour
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Automate data capture where possible
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Link release and hold to batch and spec limits
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Ensure consistent quality and traceability across all production runs
Typical project flow
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Phase 1: intake, targets, current specs and losses
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Phase 2: pilot blends and quick stabilisation
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Phase 3: lock process windows and write SOPs
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Phase 4: scale, verify KPIs and handover
Emulsion & fat systems
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Build primary emulsions with robust thermal stability
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Control particle size and phase ratio for mouthfeel
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Set shear, temperature and dwell times for repeatability
In house MDM
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Design safe low cost MDM with standard equipment
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Enhance functionality for cooked sausages and hybrids
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Document hazard controls and QC checkpoints
Organisation & training
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Role definitions for batching and emulsification
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On the job training for shear, temperature and timing
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Keep clean formulation and line records
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Ready to audit documentation
What you receive
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Formulations with dosage ranges and process windows
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Line validated SOPs and parameter sheets
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Specification pack with QC and micro schedules
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Cost to quality curves and TCO view for blends
Injection & skin fat
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Calibrate brine, pick up and massaging parameters
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Convert skin and fat to stable functional inputs
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Improve tenderness, flavour and sliceability at speed
Catering bacon systems
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Process windows for brine, pick up and tumbling
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Thermal curves that minimise cooking shrink
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Predictable yield and stable slices for foodservice
Control & KPIs
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Yield, cook loss and emulsion stability visible daily
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Deviation handling with clear response steps
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Dashboards for trial runs and scale up monitoring
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Traceable change logs for audits, reviews and customer claims
Reference topics
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Stable emulsions for frankfurters and mortadella
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PSE tolerant ham and pastrami formulations
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Catering bacon with minimal cooking shrink
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In house MDM for cooked sausages and hybrids
From Layout to Line
In Process
The photo shows Eben van Tonder working with freshly processed beef tendons. In the plant, tendons are prepared as collagen-rich functional inputs. The focus is binding strength, gel firmness and water holding capacity within defined process windows for pH, ionic strength, shear energy and thermal profile. Formulation, emulsion and dosage are validated on line, cook loss decreases and specifications remain consistent. This makes the fifth quarter technically usable and adds measurable yield and stability.