New Product Development: Vegan Nugget

Discover the potential of vegan nuggets in the food industry and the market gaps and opportunities. Learn about competitors, cost price of raw materials, ingredients, and the process for making vegan nuggets.

New Product Development: Vegan Nugget
Introduction:
The trend of vegan foods is reaching new heights with UK as the world’s first country to
have a maximum growth in plant based food consumer, so much so that 1/3rd of the Britons
has stopped eating red meat or animal meat. It’s not only UK but US, Australia and other
European countries are showing the same trend in respect to the acceptability of vegan food
products and many companies and entrepreneur has popped up in the small period of times
(Jones, 2018).
Let’s see some of the important and interesting highlights that suggest the potential of this
product and why is it becoming a new trend in the food industries:
 In US the plant based food sales grew by 801% in the year 2017.
 At the same time the plant based dairy alternative grew by 40% in the year 2017 in
the form of barley, hemp, pea, flax, quinoa, and oats.
 Similar trends are foreseeable in the growth of vegan cheese with growth projection
of compounded 7.6% rate.
 An interesting comparison can be drawn in the sales figure plant based milk that is
growing with the rate of 3% whereas on the other hand the diary milk declined by
5%..
 It was the egg alternative product that resulted in the loss of 10% for the first time in
the last 10 years to US based Jackson based company.
Trends of Vegan products in UK:
 In 2018, UK launched more vegan products than any other countries.
 The non vegan spent 645pounds more than the vegan consumer.
 92% of the plant based meals eaten by the non vegans.
 Number of vegan consumer quadrupled during the period of 2014-2018.
Market gaps & opportunities:
It is said that figure never lies; perhaps it is not manipulated or misleading. The above
figure and the competitive analysis led the NPD team to the assumption that there is lots of
scope in the vegan market which is growing and throws an opportunity for the product that
is different from the existing player.

Competitors:
Ocado Chicken Style Nuggets:
Contains gluten (Ocado)
More fat (Both)
Lesser fiber (Both)
VS
Vegan Nugget
£1.75 - 320g

No chicken Nuggets:
Competitors Analysis:
The vegetarian butcher (No chicken Nuggets) and Ocado (Chicken style Nuggets) are
existing competitors of vegan nuggets. All have certain strength in one aspect and
weaknesses on the other. As has already mentioned in the above slides Vegan chicken
style nugget contains gluten in their ingredient and many person are allergic to gluten
content, Vegan nugget has an advantage of serving gluten free content.
Both Vegetarian butcher and Ocado has higher percentage of fat and many of us tries to
avoid the high content of fat in our food product. Vegan nuggets have comparatively lower
level of fact which would put this product in an advantageous position. Vegan nuggets
have a way higher % of carbohydrate as compared to the other two competitors, contrary
£3.29 - 180g

to the myth that all carbohydrate is bad; the carbohydrate from chick pea is very good for
the cardiovascular disease and has higher fiber content.
Taking the pricing factor of both Vegetarian butcher and Vegan nuggets they are almost
similarly priced but Vegan chicken nuggets is in an advantageous position in terms of
pricing.

The INGREDIENTS for me to make the product are 100g whole meal wheat flour, 100g unsweetened soya, 25g chickpea flour, 1g rosemary,
1g salt and 0.5g cumin, 2g mustard powder. The above experiments are done by using above ingredients in a crumb coating. All together 150
people are called to taste the sample those included food scientist, food expert and people from the food industry to get their feedback.
Feedback: mustard flavor too strong after food making process and lacks the required aroma.
Cost price of raw material:

Ingredien
t
Quantit
y
Unit
cost
in
GB/k
g
Cost/g/
item
Uni
t
recip
e wt.
g/ite
m
%
recip
e
AP
weigh
t in
kg
Trim
weigh
t in
gram
EP
weigh
t in
gram
Yeil
d %
factor=100/yeild
%
EP
Cost
Wheat
flour 100g 6.15 0.006 KG 100g 40 1 100 900 90 1.11 6.82
Soya 100g 8 0.008 KG 100g 40 1 50 950 95 1.05 8.4
Chickpea
flour 25g 6.15 0.006 KG 25g 10 1 100 900 90 1.11 6.82
Cornflake
s 15g 3.75 0.003 KG 15g 6 1 50 950 95 1.05 3.93
Rosemary 1g 77.5 0.007 KG 1g 0.5 1 20 980 98 1.02
79.0
5

Mustard
Powder 2g 7.27 0.007 KG 2g 0.8 1 50 950 95 1.05 7.63
salt 1g 0.46 0.004 KG 1g 0.5 1 50 950 95 1.05 0.48
cumin 3g 6 0.006 KG 3g 1.2 1 50 950 95 1.05 6.3
247g 100 119
Cost per KG=EP Cost/Total KG
Cost per KG=119/8=14.87 GBP
Cost per recipe per gram=0.12
Cost of 247g=247x0.12=29.64

Cost Price of raw material-2nd Experiment:
Ingredien
t
Quantit
y
Unit
cost
in
GB/k
g
Cost/g/
item
Uni
t
recip
e wt.
g/ite
m
%
recip
e
AP
weigh
t in
kg
Trim
weigh
t in
gram
EP
weigh
t in
gram
Yeil
d %
factor=100/yeild
%
EP
Cost
Wheat
flour 100g 6.15 0.006 KG 100g 40.81 1 100 900 90 1.11 6.82
Soya 100g 8 0.008 KG 100g 40.81 1 50 950 95 1.05 8.4
Chickpea
flour 25g 6.15 0.006 KG 25g 10.20 1 100 900 90 1.11 6.82
Cornflake
s 15g 3.75 0.003 KG 15g 6.12 1 50 950 95 1.05 3.93
Rosemary 1g 77.5 0.007 KG 1g 0.4 1 20 980 98 1.02
79.0
5

salt 1g 0.46 0.004 KG 1g 0.4 1 50 950 95 1.05 0.48
cumin 3g 6 0.006 KG 3g 1.26 1 50 950 95 1.05 6.3
245g 100 112
Cost per KG=EP Cost/Total KG
Cost per KG=112/7=16 GBP
Cost per recipe per gram=0.11
Cost of 247g=245x0.11=26.95 GBP

INGREDIENTS for me to make the product are 100g whole meal wheat flour, 100g unsweetened soya, 25g chickpea flour, 1g rosemary, 1g
salt and 0.5g cumin. . By mixing and shaping all the ingredients given above I will coat and bake the mixture at 150 degree Celsius, mustard
will not be taken for the second experiment.
Feedback: Cumin flavor too strong after food making process and lacks the required aroma.

Cost Price of raw material-3nd Experiment:

Ingredient
Unit
Kg/g/l Quantity
Unit
cost in
GB/kg Cost/g/item Unit
recipe
wt.
g/ite
m
%
recipe
AP
weight
in kg
Trim
weight
in
gram
EP
weigh
t in
gram
Yeild
% factor=100/yeild%
EP
Cost
Wheat flour KG 100g 6.15 0.006 KG 100g 38.09 1 100 900 90 1.11 6.82
Soya KG 100g 8 0.008 KG 100g 38.09 1 50 950 95 1.05 8.4
Chickpea
flour KG 25g 6.15 0.006 KG 25g 9.52 1 100 900 90 1.11 6.82
Cornflakes KG 15g 3.75 0.003 KG 15g 5.71 1 50 950 95 1.05 3.93
Rosemary KG 1g 77.5 0.007 KG 1g 0.38 1 20 980 98 1.02 79.05
Onion KG 10g 0.85 0.0008 KG 10g 3.8 1 100 900 90 1.11 0.94
Red Bell
Paper KG 10g 1.76 0.001 KG 10g 3.8 1 100 900 90 1.11 1.95
salt KG 1g 0.46 0.004 KG 1g 0.38 1 50 950 95 1.05 0.48
cumin KG 0.5g 6 0.006 KG 0.5 0.23 1 50 950 95 1.05 6.3

262.5
114.6
9

Ingredients Process
BLEND
Mix &
SHAPE
COATIN
G
BAKE
Onion &
bell
pepper,
baked
100
g
100
g 25g 15g
0.5
g
1g 10g 10g 1g
3rd-Experiment

The ingredients for me to make the product are 100g whole meal wheat flour, 100g unsweetened soya, 25g chickpea flour, 15g cornflakes,
1g rosemary, 10g onion, 10g red bell pepper, 1g salt and 0.5g cumin. In order to reduce the flavor of cumin and increase the aroma, the
quantity of cumin has been reduced in my 3rd experiment and onion and bell paper has been added to increase the aroma.
I will prepare and scale all the ingredients before the making process
TI will prepare and scale all the ingredients before starting food making process.
To ensure this product can last for 1 month. First, I Will fry onion and red bell pepper at 150 degree celsius for 20mins to extract the juice.
After that, pour the blended mixture and mix together with whole meal flour, chickpea flour, rosemary, salt, cumin and the soya.
Lastly, shape and coat with cornflake and bake for 20 minutes at 160 Celsius degree. And it ready for tasting.

Continue investigate:
Low Fat
High Fibre

Vegan nugget meets the high fiber and low-fat health claim and has gluten free ingredients with low sugar contents.
A claim that a food is high in protein, at least 20% of the energy value of the food is provided by protein.
I am going to continue the research on the high protein ingredient to reach the claim.
And the texture of nuggets is crunchy but the taste is flavorless and I will continue to investigate and use the natural seasoning to the
enhanced aroma of the nugget.
Vegan nugget meets the high fiber and low-fat health claim and has gluten free ingredients with low sugar contents.
A claim that a food is high in protein, at least 20% of the energy value of the food is provided by protein.

v
Table 1: Development diary
Week: Date:
Topics Observations
Initial ideas
Formulation
Preliminary costing
Process
Packaging and labelling comments
Brand
Areas for improvement
Next steps
Ingredients for next week
4th 14/05/2019
To add protein by
adding chickpea
100g wholemeal wheat flour, 100g unsweetened soya, 25g
chickpea flour, 20g chickpea canned, 15g cornflakes, 1g
rosemary, 10g onion, 10g red bell pepper, 1g salt and 0.5g
cumin
34 GBP/recipe High protein, low fat, aroma and taste matched, no
gluten, and high carbohydrate.
Ready to be launched and packaged.

Cost Price of raw material- 4th Experiment:
Ingredient Unit Kg/g/l Quantity
Unit
cost in
GB/kg Cost/g/item Unit
recipe wt.
g/item
%
recipe
AP
weight in
kg
Trim
weight in
gram
EP
weight in
gram Yeild % factor=100/yeild% EP Cost
Wheat flour KG 100g 6.15 0.006 KG 100g 38.09 1 100 900 90 1.11 6.82
Soya KG 100g 8 0.008 KG 100g 38.09 1 50 950 95 1.05 8.4
Chickpea
flour KG 25g 6.15 0.006 KG 25g 9.52 1 100 900 90 1.11 6.82
Cornflakes KG 15g 3.75 0.003 KG 15g 5.71 1 50 950 95 1.05 3.93
Rosemary KG 1g 77.5 0.007 KG 1g 0.38 1 20 980 98 1.02 79.05
Onion KG 10g 0.85 0.0008 KG 10g 3.8 1 100 900 90 1.11 0.94

Red Bell
Paper KG 10g 1.76 0.001 KG 10g 3.8 1 100 900 90 1.11 1.95
salt KG 1g 0.46 0.004 KG 1g 0.38 1 50 950 95 1.05 0.48
cumin KG 0.5g 6 0.006 KG 0.5 0.23 1 50 950 95 1.05 6.3
262.5 114.69
Cost per KG=EP Cost/Total KG
Cost per KG=122.32/10=12.2GBP
Cost per recipe per gram=0.12
Cost of 282.5g=282.5x0.12=34 GBP
Cost price of raw material: 4th Experiment

Ingredients Process
BLEND
Mix &
SHAPE
COATING
BAKE
Onion &
bell
pepper,
baked
100
g
100
g 25g 15g20g
0.5
g
1g 10g 10g 1g

The INGREDIENTS for me to make the product are 100g wholemeal wheat flour, 100g
unsweetened soya, 25g chickpea flour, 20g chickpea, 15g cornflakes, 1g rosemary, 10g
onion, 10g red bell pepper, 1g salt and 0.5g cumin.
I will prepare and scale all the ingredients before the making process
To ensure this product can last for 1 month. First, I Will bake onion and red bell pepper at
150 Celsius degree for 20mins to extract the juice.
While onion and bell pepper are ready I will blend them together with chickpea and 20g
soya.
After that, pour the blended mixture and mix together with whole meal flour, chickpea
flour, rosemary, salt, cumin and the soya.
Lastly, shape and coat with cornflake and bake for 20 minutes at 160 Celsius degree. And
it ready for tasting.
The ingredients for me to make the product are 100g whole meal wheat flour, 100g
unsweetened soya, 25g chickpea flour, 20g chickpea, 15g cornflakes, 1g rosemary, 10g
onion, 10g red bell pepper, 1g salt and 0.5g cumin.
I will prepare and scale all the ingredients before the making process
To ensure this product can last for 1 month. First, I Will bake onion and red bell pepper at
150 Celsius degree for 20mins to extract the juice.
While onion and bell pepper are ready I will blend them together with chickpea and 20g
soya.
After that, pour the blended mixture and mix together with whole meal flour, chickpea
flour, rosemary, salt, cumin and the soya.
Lastly, shape and coat with cornflake and bake for 20 minutes at 160 Celsius degree. And
it ready for tasting.

Implementing HACCP Plan in the production facility:

HACCP plan:
The purpose of the HACCP plan is to ensure safe, healthy and clean foods to the end
consumer through the implementation of the plan in the production facility. First of all
identifying the hazards weather chemical, biological or physical that are unsafe for the
consumption are identified, for instance the raw material purchased may have bacteria,
pathogens etc. So identification of a several control points (CCP), like ensuring the factory
floor is clean and sterile, machines are covered when not in use then after establishing a
critical limit to which the different hazard are controlled to adjust the hazard to an
acceptable limit. This process can be performed by heating and cooling the industrial oven
cyclically. This ensures the activation of the ingredients as well as controlling the hazards
through the same process. Monitoring is an essential feature of the HACCP plan and needs
to be listed in the HACCP plan. This can be done through testing or data from the software
that indicates the criticality to intervention as a corrective measure. Weather the whole
plan is working in accordance to its objective i.e. to ensure safe foods requires validation
and the validation are done through sampling e.g. microbial testing as one of the several
test for verification. All these activities requires documentation and record keeping such as
identification of hazards, control points, verification report, validation report to be part of
the daily work.
Labeling & Packaging (Govt. guidelines & compliances):
 Clear & precise information
 Warning for allergic
 Shelf life to be mentioned
 Compulsory ingredient information

The packaging of the Brit vegan would follow the instructions and guidelines of the
standard government procedure which would be clear, precise, understandable and not
misleading. In the above sample it is clearly visible the name of the food, expiry date,
warnings for the allergic or non-gluten consumer, list of ingredients and vitamins, it also
follows the name and address of the manufacturer, packer or seller, lot number, storage or
cooking instructions. The label should have compulsory information of ingredients in
g/mg/kg or l/ml as the case would be.
Labeling:
Energy 778 kJ
184kcal
934kJ
221kcal
Carbohydrate
(30.3%)/100g
Sugars
(2.3%)/100g
Protein
(8.1%)/100g
30.3g
2.3g
8.1g
36.36g
2.8g
9.72g
Fiber
(6.1%)/100g
Fat
(2.1%)/100g
Of which
saturates(0.3%/100g
)
6.1g
2.1g
0.3g
7.32g
2.52g
0.36g

Salt 0.58g 0.69g
0..58%/100g
Potassium
Sodium
Vitamin A
Vitamin C
2.47%
0.41%
1.52%
1.03%
2.96%
0.50%
1.82%
1.23%
Product Name
Vegan nuggets
Ingredients:
whole meal wheat flour(35.4%), unsweetened soya (35.4%), chickpea flour (8.8%),
chickpea(7.8%), cornflakes, onion, red bell pepper, rosemary, salt, cumin.
Food Allergens
For the allergens see ingredients in bold
Net Quantity
120 grams
Best Before
1 month from the date of manufacture
Storage Condition
Keep it cold under 5ºC. Once open you have to consume within 2 days.
Cook Before eating
Fry: on a medium heat for 4 mins.
Oven: 160ºC for 8mins
Produce in the UK for Vegan Nugget, London, ME44HZ, UK.

Note:
This LABELLING has been complied with the EU Regulation 1169/2011 (FIR 2011). All
mandatory list are on my packaging. the mandatory list is including product name,
ingredients, allergens, quantitative ingredient declaration, net quantity, storage, business
name and address, origin, instruction for use and nutrition information.
Note:
I have chosen CPET as packaging. it is because It can take foods directly from the freezer
to oven.
CPET can stand at least 200 Celsius degrees. So, Nuggets can be heated up and directly
harm the package. it is user- friendly and convenient
It has a pet lid film. It has a high oxygen barrier so it can retain the quality of food.
According to the samples, the labeling will be printed on the paper. So easy for recycling
and it is environment-friendly.

Ingredient Analysis:
“Protein is King”-(Dr. Spencer Nadolsky, 2018), Protein is the most important source of
energy. If we don’t get enough protein in our diet, the composition and our health suffer.
The DRI (Dietary Reference Intake) recommendation on daily intake of protein 56g/per
day for an adult man and 46g/day for a women. The Vegan Nugget has a considerable
high protein % every 100g that can be a vital source of our daily requirement.
Increasing the fiber intake in our foods is related to lower risk of cardiovascular disease,
stroke, type2 diabetes and cancer related to bowel. The government guidelines in this
regard is that we should take 30g of fiber on the daily basis. The vegan nugget provides 6
gm/100g of fiber as a source to fiber requirement.
Added sugar is one of the worst requirements in our daily diet intake. It provides calories
with no nutrients and has a negative impact on the metabolism of the body. Vegan nugget
has been prepared to be low in sugar.
Ingredient Analysis-1
HighFiberLowSugarGluttonFreeHighCarbohydrateLowSugarPotassium2.46%VitaminA1.52%

Vegan nugget is gluten free which are good for the people with gluten allergy and can
change the microbiome, reduces gastrointestinal discomfort which can result in reducing
weight.
Ingredient Analysis-2:
High carbohydrate
Low potassium
Low Vitamin A & C
Carbohydrates are said to be the cause of obesity epidemic but not all carbohydrate are bad
for health especially from the high carbohydrate food such as chickpeas that contain
27.4% of carbohydrate/100g in which 8% are fiber. Chickpeas used in the Vegan nugget
are a good source of protein and vitamins such as Iron, phosphorus and Vitamin B that is
really beneficial to health.
Vitamins are the important nutrients that should be taken in a balanced way so as to lead a
healthy life. Considerable amount of Vitamin A is associated with protecting some of the
chronic disease such as lung cancer. Presence of Vitamin C is also related to prevent
cancer and other chronic disease especially the stomach related disease such as stomach
cancer. Lack of vitamin is the grey area in the preparation of vegan nuggets but is rich in
the other ingredients that are very beneficial to our health.
Conclusion:
As has been already discussed in the introductory part of this report we can easily assess
that there is already a trend in capturing the vegan market but the question here arises as to
what has led to spurt in the consumption of plant based food, especially the western
countries? The answer lays in the fact that growing awareness of animal cruelty,
misbalances in the eco-system, climate change and the upcoming data of food scientist on
the cancerous effect of red meat on health is all contributing to the change of eating habits

of people. This is already evident from the growth trajectory of plant based food product
(Chirnado, 2018). On the other hand, vegetable being the source not only of protein but
also to important vitamins, fiber and nutrients that are antioxidant and antiseptic. Vegan
nugget sees this trend as an opportunity and has a very confident view as to say sky is the
limit.
Referances:
Jones, L ( June 2018) Veganism: Why Is It On The Up. Available from:
https://www.bbc.co.uk/news/business-44488051 (accessed 26 March 2019).
Chiorando, M ( September 2018) Massive Demand For Vegan Food Is Leading A Retail
Revolution. Available from: https://www.plantbasednews.org/post/icelands-vegan-range-
launches-dedicated-plant-based-section (accessed 26 March 2019).
Labeling & Packaging
(Govt. guidelines &
compliances