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Swadlincote Site

Food Supplement Innovation Nick Bennett RNutr.

Food Matters Live, November 2014

Introduction

• Brunel Healthcare is the largest contract manufacturer of food supplements in the UK

• Supplying the majority of own label products to the mass market.

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• We will briefly look at our steps to innovation….

Turning an idea into a finished product

• What is innovation?

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• Examples of innovative materials

• Building the supply chain

• Manufacture – materials and formats

• Compliance – opportunities and limitations

What is innovation? • Two sub categories:

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• NPD - Working within the confines of existing regulations – Incremental development – Maximising benefits of existing claims

• Innovation – developing new solutions to change the status quo. – Research into new materials to win new claims – Effectively promoting scientifically researched materials to

communicate their benefits without claims.

Communication Manufacture Dosage

Idea New function New material

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Hurdles to launching new supplements

How do we innovate?

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• NPD – Gap analysis – Market review of successful products – Maximising benefits of existing claims

• Innovation – Search the globe – Collaborate with raw material manufacturers to encourage new claims – Identify scientifically researched materials to provide improved product

benefits.

By building the innovation supply chain

THE SUPPLY CHAIN

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The supply chain Step 1

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The idea

Generate idea and check its practicality

Collaborate

Investigate and research

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New function – prove it!

The supply chain Step 2

Funding? Innovate UK (TSB)? Own the research or collaborate

Novel food – prove it is safe!

Test and present 10

Build the interest

The supply chain Step 3

Secure the supply chain

Small scale manufacture 11

Demonstrating a finished product always engages marketing more than just a concept.

The supply chain Step 4

Larger scale trials with the backing of the supply chain

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Trials to prove safety, efficacy and possibly get a claim

The supply chain Step 5

Scale up manufacture 13

Get all the pieces of the supply chain in place

The supply chain Step 6

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The supply chain Step 7

Packing, Warehousing and Distribution

Engage with the consumer 15

Retail listings and sales through PR and promotion

The supply chain Step 8

MANUFACTURING IN MORE DETAIL

Brunel Healthcare

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Tablet Manufacturing DISPENSING

•3 Dispensing bays.

GRANULATION

•5 Granulation suites.

•3 Fluid bed dryers.

•2 Oven bed dryers.

BLENDING

• Drum Blending.

• Cone Blending.

• IBC Blending.

COMPRESSION

•18 tablet compression machines.

•Variety of shapes and sizes available.

COATING

•7 coating machines, including 3 dual sugar/film coaters.

• Purpose built 3,000m2 tablet facility – fully operational since 1996.

• Installed tablet capacity for 3.5 billion tablets per annum.

• Expansion space available for a total capacity in excess of 6.5 billion tablets.

Capsule Manufacturing CHECKING

FILLING

DRYING BLENDING

DISPENSING

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Swadlincote Site

Goods-in

Goods-out

Brunel Healthcare Packing Site

COMPLIANCE Brunel New Product Presentation

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Manufacturing standards

• Food - HACCP, Safety, Allergen control, BRC

• Pharma – MHRA, FDA, GMP, Positive release of all

products

• Best of both - Stability, efficacy and safety. Compliant to highest standards.

Regulations – Actives and Additives

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Novel?

Dose?

Claimable?

Sustainable?

Approved additive?

E number compliant?

Allergenic? Sustainable? Stable?

Trade Organisation Memberships

European Federation of

Associations of Health

Product Manufacturers

INNOVATIONS – NEW MATERIALS

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Health Claims – get over this barrier to advertise the products benefit.

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Beta glucan – a natural extract from yeast which optimises the immune system. Intended claim

“Anti-pathogenic effect”.

Fruitflow – a water soluble Tomato Concentrate, “helps maintain normal platelet aggregation, which contributes to healthy blood flow”

Conclusion…. • Truly innovative foods are rare.

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• But, it can be done, it just requires upfront planning.

• Plan and work out the details,

• Comply with the regulations

• Build a supply chain!

• Overcome the hurdles and succeed!

ANNEX Brunel New Product Presentation

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Legislation • It is expected by the consumer and fundamental to good practice that all raw

materials and products must:

1. Comply with all current European legislation applicable to food supplements. *

2. Not have been treated with irradiation of any kind nor come into contact with irradiated materials.

3. Not include ingredients that are genetically modified (GM) nor derived from GM organisms.

4. Comply with relevant purity standards where ingredients have an E number under EU food additive regulations.

* this includes, but is not limited to the following regulations:

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Regulations and Best practice • Good Manufacturing Practices - EEC Guide Volume IV • Good Warehousing Practices - PQG Monograph • Good Laboratory Practices - EEC Guide Volume IV • Food Safety Act 1990 • Weights and Measures Act 1985 • EC Regulation 258/97 on Novel Foods • EC Regulation 1169/2011 on the provision of food information to consumers • EC Regulation 1924/2006 on Nutrition and Health Claims • EC Directive 89/396/EC Indications or Marks Identifying the Lot to which a Foodstuff Belongs • EC Regulation 178/2002/EC General Principles and Requirements of Food Law • EC Directive 2002/46 EC Approximation of the Laws of the Member States relating to Food Supplements • EC Regulation 1924/2006/EC Nutrition & Health Claims made on Foods • EC Regulation 1129/2011 and 1130/2011 for food additives and associated purity criteria 231/2012 • EC Regulation 1881/2006/EC Setting Maximum Levels for Certain Contaminants in Foodstuffs (including limits on Heavy Metals in Food Supplements) • EC Regulation 396/2005/EC Maximum Residue Levels of Pesticides in or on Food or Feed of Plant and Animal Origin • EC Regulation 999/2001/EC Prevention, Control and Eradication of Certain Transmissible Spongiform Encephalopathies • EC Regulation 1829/2003 and 1830/2003/EC Genetically Modified Feed and Food • EC Directive 1999/2/EC Foods and Food Ingredients Treated with Ionising Radiation • EC Regulation 1935/2004/EC Materials and Articles Intended to come into Contact with Food • IADSA / EHPM / FSE / CRN Quality Guide

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