Case Studies

Executive Summary

Our client, a Maryland-based start-up, secured a deal with Mark Cuban on Shark Tank to launch their plant-based burgers. At the time, they were hand-producing these burgers in a commissary kitchen. The product was originally developed and sold by the culinary team without a scalable recipe.

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The CSI Partners stepped in to reformulate the product using commercial ingredients, ensuring it matched the original culinary version in flavor, texture, and appearance while being suitable for large-scale production. We designed and developed product packaging, tested shelf life, and created a nutritional facts panel with appropriate claims and identified a manufacturing facility, all within an aggressive timeline to ensure the products were retail-ready for the show’s airing.

The CSI Partners’ efforts were so successful that the client retained us for all future Research & Development efforts on the business.  Over the next four years, our firm went on to develop, launch, and commercialize an entire platform for the brand, including Plant-Based Sausages, Plant-Based Chicken Nuggets and Tenders, Plant-Based Ground, Plant-Based Beverages, and Plant-Based Burger Sauce.

 

Client Background

Everything Legendary is a Maryland-based start-up with a mission rooted in personal experience. The founders, driven by a passion for health and wellness, sought to create a plant-based product that didn’t compromise on taste. The idea was born when co-founder Cheers struggled to find a plant-based burger that satisfied his mother’s cravings during her battle with illness. Determined to fill this gap, Cheers partnered with a chef to develop a burger that was both delicious and nutritious. The product, initially made in small batches in a commissary kitchen, quickly gained local popularity. Their big break came when they secured a deal with Mark Cuban on Shark Tank, setting the stage for a rapid scale-up and nationwide distribution.

 

The Challenge

The client needed to create a commercially viable product that replicated the flavor and texture of the original hand-made version. This task had to be completed within a highly aggressive timeline, with additional requirements to scale up production and develop engaging, standout packaging. All while no one on the founder team’s had food industry experience. 

 

The Solution

Given that the original product was crafted by the chef team without a documented recipe, our first step was to observe and document the production process of the gold-standard burger. We then evaluated the ingredients used, identifying those that needed to be replaced or removed for commercial readiness. Additionally, we determined which ingredients were necessary for extending shelf life and optimizing texture.

After stabilizing the base recipe, we collaborated with the culinary team to incorporate commercial-ready ingredients that maintained the flavor profile of the original product. We then identified a co-manufacturing facility capable of conducting feasibility trials on small batches and managing production at scale.

Since the client had no prior experience in the food industry, The CSI Partners handled all aspects of commercialization, including ingredient procurement, packaging design and development, product costing, manufacturing scale-up, and quality process development and review.

 

Implementation

The commercialization process was successfully implemented with a cost-effective recipe using commercial ingredients. The CSI Partners functioned as the client's supply chain team, sourcing necessary ingredients while maintaining cost competitiveness. The entire implementation was completed within the projected timeline, ensuring the product was ready in time for the show’s airing.

 

The Results

The CSI Partners led to the successful nationwide introduction of the plant-based burger, extending distribution to over 5,600 retail and food service locations. The product’s success paved the way for further collaboration, leading to the development and commercialization of an entire product platform, including Plant-Based Sausages, Chicken Nuggets and Tenders, Ground, Beverages, and Burger Sauce.

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Conclusion

This case study exemplifies The CSI Partners' ability to rapidly and effectively commercialize food products from a concept stage to nationwide distribution. By providing comprehensive consulting services—from reformulation to supply chain management and packaging design—we helped Everything Legendary scale their business from a start-up to a significant player in the plant-based food industry. Whether you're looking to develop a new product or expand an existing line, our expertise can guide your project to success.

Executive Summary

Rebel Cheese, a leader in the vegan cheese market, sought to extend the shelf life of their top-selling Vegan Brie and Truffle Brie cheeses. The cheeses were experiencing softening and syneresis during curing and at various points in their shelf life, which the company was unable to diagnose. The CSI Partners collaborated with Rebel Cheese to assess the recipe and recommend functional ingredients that would enhance texture and prolong shelf life. Upon implementing these recommendations, Rebel Cheese saw immediate improvements in both texture and shelf life, leading them to extend their partnership with the CSI Partners across their entire product line.

 

Client Background

Rebel Cheese is a pioneering brand in the vegan cheese industry, offering a wide array of plant-based products, including Firm Cheese, Chevres, Fromages, Dips & Spreads, and Soft Cheese. Recently, the company secured investment from Mark Cuban on Shark Tank and is now poised for significant product expansion. Among their most popular products are the Brie and Truffle Brie cheeses, which are part of their Soft Cheese line. Rebel Cheese aimed to extend the shelf life of these products to remain competitive in the growing plant-based market.

 

The Challenge

Rebel Cheese set out to increase the shelf life of their Vegan Brie and Truffle Brie cheeses from 60 days to approximately 100 days, aligning them more closely with their conventional counterparts. Additionally, the company sought to update their packaging graphics to comply with FDA regulations. The primary challenge was identifying the root causes of softening and syneresis and finding a solution that would not compromise the product’s quality.

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The Solution

Our team conducted a comprehensive review of the formulation and production process for both the Vegan Brie and Truffle Brie cheeses. We compared the composition and analytical profiles of these products with those of conventional brie cheeses from market leaders. This analysis revealed significant differences in moisture, fat, salt, protein, and ash content, guiding us to focus on these parameters for optimization.

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The investigation identified that the moisture content in the vegan brie was considerably higher than in conventional brie, leading to syneresis and adversely affecting shelf life. To address this, we explored several strategies: reducing added water, incorporating additional protein sources to increase enzymatic activity (thereby promoting protein-protein and water-protein bonds), and evaluating hydrocolloids to bind excess water in the formulation.

 

Implementation

We designed a series of experiments to test the impact of moisture reduction, additional protein incorporation, and hydrocolloid use. These experiments included a cost analysis and an assessment of potential effects on texture and organoleptic properties. Each test was meticulously documented and conducted by Rebel Cheese’s cheesemakers. The results underwent rigorous organoleptic testing and analytical analysis to ensure product quality was maintained.

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Results

The formulation with the added vegetable protein demonstrated outstanding performance. It effectively reduced moisture content without altering the flavor profile. Over the product’s shelf life, the cheese remained drier, and the discoloration issue was resolved. The successful outcome of this optimization not only extended the shelf life of the Vegan Brie and Truffle Brie cheeses but also enhanced their overall quality.

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Conclusion

Through our detailed analysis and targeted experimentation, CSI Partners helped Rebel Cheese achieve their goal of extending the shelf life of their Vegan Brie and Truffle Brie cheeses while maintaining product quality. The success of this project underscores the importance of precise formulation adjustments in plant-based product development. Rebel Cheese’s decision to expand our collaboration to include all products in their lineup reflects the value of our technical expertise in driving innovation and growth in the vegan cheese industry.

Executive Summary

Our client, a New Jersey-based start-up, sought to commercialize a vegan chili product that had become a fan favorite at social gatherings. Driven by a personal health journey, the founders developed a recipe that was not only delicious but also made with natural ingredients and free from preservatives. The CSI Partners collaborated with the client to create a comprehensive strategy for launching a line of vegan chilis. This included developing product branding, building the business case, and expanding the product line with two additional SKUs.

 

Our involvement extended to identifying a manufacturing facility, designing and developing product packaging, testing shelf life, and creating a nutritional facts panel with appropriate claims.

 

Client Background

Mitch Wolinsky, now better known as Chef Manolo, embarked on a quest to improve his diet through plant-based foods after finding the selection of ready-to-eat vegan dishes in stores lacking. His journey led to the creation of a nutritious, plant-based chili recipe made with high-quality ingredients that was vegan, gluten-free, and soy-free. Designed to be free of the top eight most common allergens, Chef Manolo's dishes were ideal not only for vegans but also for individuals with food allergies, mirroring his own dietary restrictions. After showcasing his chili at various charity events, the overwhelming demand from attendees sparked the idea to bring the product to market, initiating the development journey with The CSI Partners.

 

The Challenge

While Mitch had a great-tasting vegan chili, he lacked a brand identity, product proposition, pricing structure, and promotional strategy. Despite his business acumen, his experience in the food industry and product commercialization was limited. Before launching the vegan chili line, it was crucial to differentiate the product from existing market offerings and expand the line beyond a single variety.

Additionally, Mitch was looking to create a business that he boot strapped and without taking on additional investors or seeking debt, so budgets were always very slim.

 

The Solution

Starting with a strong recipe, The CSI Partners worked closely with Mitch to develop his product proposition. We assembled a team of product development scientists, chefs, and nutritionists and embarked on a food tour in Philadelphia. This tour allowed us to explore flavor trends in the vegan and soup markets and gain insights into the grocery and convenience store landscapes.

Leveraging our findings from the food tour and market analysis, our team brainstormed the components of a go-to-market strategy, including product offerings, value proposition, pricing, packaging configuration, and product line expansion. Once we finalized the format and selected four SKUs, The CSI Partners' development team crafted commercially viable versions of the three additional SKUs, which were approved by Mitch and his team.

All of this work was done in a very cost-effective way to deliver the solution the client needed without breaking the budget. 

 

Implementation

We partnered with Mitch and Manolo’s best through all stages of growth as he diligently brought his product to market.  The CSI Team scaled the level of support to suit the timing and budget as the business grew.    

We facilitated the scale-up and commercialization of the SKUs, transitioning from a commercial kitchen and eventually to a production facility capable of supporting the introduction of the vegan line at Whole Foods' hot bar, and eventually, the retail perimeter refrigerated soup aisle. This process included finalizing formulations, selecting packaging, developing packaging content (including nutritional facts panels, ingredient statements, and validating claims), and providing initial pricing recommendations to ensure profitability, creation of a HACCP plan for their commercial kitchen to eventually conduct feasibility trials at the co-manufacturing partner. 

 

The Results

In January 2017, Whole Foods began selling Chef Manolo’s chili at their soup bar. By the end of 2017, Manolo’s Best Farmstand Chili and Soups had gained enthusiastic customers in seven additional Whole Foods stores across the greater Philadelphia region. By the close of 2018, the product line was available in every Whole Foods store in the region, from Lancaster, PA to Cherry Hill, NJ, quickly becoming one of the bestselling new products in the area.

In 2019, Mitch partnered with Winter Gardens Quality Foods to produce and co-pack his chili and soup.  The CSI Partners lead the feasibility testing of recipes, costing validation and ingredient procurement of the products launched for Manolos, partnering with the operations team at the copacker.  This partnership led to Chef Manolo’s products being stocked on the shelves of nearly two hundred Whole Foods stores in the Midwest and North East regions. 

 

Conclusion

The success of Chef Manolo’s vegan chili line exemplifies the power of collaboration, strategic market analysis, and diligent execution. By working closely with The CSI Partners, Mitch was able to transform a beloved recipe into a commercially viable product line that met market demands and scaled to multiple regions. The result is a thriving brand that continues to grow, providing delicious, allergen-free vegan options to a broader audience. Chef Manolo’s journey underscores the importance of expert guidance in navigating the complexities of food product commercialization, ultimately leading to sustainable growth and market success.