Protocol Raw — Home Pilot Protocol¶

Document ID: SOP-PILOT-v1.1
Last Updated: February 2026
Classification: CONFIDENTIAL

Purpose¶

This document provides step-by-step instructions for executing a 10kg pilot batch at home to validate the Protocol Raw Complete formulation (GI-stable version: reduced yeast + whole-food fibre system) before co-packer production.

Objectives: 1. Produce a representative sample for laboratory nutritional analysis 2. Verify processing workflow and timing 3. Validate Functional Pack preparation 4. Assess finished product characteristics

1. Equipment Required¶

1.1 Essential Equipment¶

Equipment	Specification	Estimated Cost
Meat grinder	8-10mm plate, min 100kg/hr capacity	£200-400
Mixing bowl/container	15-20L food-grade	£20-40
Digital scales (large)	0-15kg, ±10g accuracy	£30-50
Digital scales (precision)	0-500g, ±0.1g accuracy	£20-30
Freezer-safe packing	Vacuum sealer + bags OR rigid freezer tubs	£20-300
Labels/marker	Freezer-safe	£5-15
Probe thermometer	Digital, -50°C to +150°C	£15-25
Freezer	Capable of -18°C	Existing

2. Ingredient Quantities (10kg Batch)¶

2.1 Main Ingredients (Meats/Organs + Egg)¶

Ingredient	%	Weight (g)
Bone-in Chicken Mince	23.0%	2,300
Beef Heart	19.9%	1,990
Beef Trim (60/40)	16.2%	1,620
Chicken Skin (fat-on)	10.1%	1,010
Chicken Gizzards	7.0%	700
Green Beef Tripe	4.3%	430
Beef Kidney/Spleen (75/25 blend)	6.0%	600
Beef Liver	2.7%	270
Whole Egg (beaten)	2.7%	270
SUBTOTAL	92.8%	9,280

2.2 Functional Pack A — Dry Preblend (GI-Stable)¶

Ingredient	%	Weight (g)
Nutritional Yeast	3.0%	300
Pumpkin Powder or Carrot Fibre	2.0%	200
Psyllium Husk	0.5%	50
Sunflower Seed Meal	1.0%	100
Oyster Powder	0.35%	35
Mussel Powder	0.10%	10
Kelp Meal	0.05%	5
PACK A TOTAL	7.0%	700

Pilot note: Run the pilot with either pumpkin powder or carrot fibre (not both) and record which was used for lab traceability and texture/GI observations.

2.3 Functional Pack B — Oils (no additives)¶

Ingredient	%	Weight (g)
Fish Oil	0.8%	80
Cod Liver Oil	0.2%	20
Flaxseed Oil	0.1%	10
PACK B TOTAL	1.1%	110

TOTAL BATCH: 10,000g

3. Pre-Production Checklist¶

[ ] All ingredients sourced and inspected
[ ] Lot numbers recorded
[ ] Frozen ingredients tempered in fridge 24-48 hours
[ ] Grinder assembled with 8-10mm plate
[ ] Scales calibrated
[ ] Packing equipment tested (vacuum sealer or tubs ready)
[ ] Workspace cleaned and sanitised
[ ] Freezer space cleared

4. Production Procedure¶

Step 1: Prepare Functional Packs (15 min)¶

Pack A: 1. Weigh each dry ingredient on precision scales 2. Combine in bowl, mix 2-3 minutes until uniform 3. Transfer to labelled bag

Pack B: 1. Combine fish oil, CLO, flaxseed oil 2. Store refrigerated until use

Step 2: Prepare Main Ingredients (30 min)¶

Remove ingredients from refrigerator
Check core temperature: -2°C to +2°C
Weigh each ingredient into separate containers
Beat eggs in separate bowl

Step 3: Grind (45 min)¶

Grind in order (8-10mm plate): 1. Bone-in chicken mince 2. Beef heart 3. Beef trim 4. Chicken skin 5. Chicken gizzards 6. Green beef tripe 7. Beef kidney/spleen 8. Beef liver

Check temperature ≤4°C after grinding

Step 4: Create Masterbatch (10 min)¶

Transfer ~3.0 kg ground mix to a separate bowl (acceptable range 2.5–4.0 kg)
Add entire Pack A (700 g) in 2–4 increments, mixing between additions
Mix thoroughly 4–6 minutes until no clumps/gel pockets are visible and powder is evenly dispersed

Step 5: Final Mix (15 min)¶

Return masterbatch to main mix
Combine beaten eggs with Pack B oils
Pour over mix
Mix 4-5 minutes until uniform

Check temperature ≤4°C after mixing

Step 6: Portion and Pack (30 min)¶

Portion into 500g units (±10g)
Pack into vacuum bags or rigid freezer tubs
Seal/close immediately
Label: "PR Pilot — [Date] — Unit #"
Transfer to freezer immediately

Expected yield: 20 × 500g units

Step 7: Freeze¶

Arrange in single layer until frozen solid
Freezer set to -18°C or colder
Minimum 12 hours to reach core temperature

5. Sample Collection for Lab¶

Composite Sample Method¶

After freezing, select 6 units at random
Thaw in refrigerator (24 hours)
Take ~50g from each unit
Combine = 300g composite sample
Mix thoroughly
Submit to lab

Lab Panel Request¶

Proximate: Moisture, protein, fat, ash, fibre

Minerals: Ca, P, Zn, Mn, Cu, Se, I

Fatty Acids: EPA, DHA, linoleic

Vitamins: D, E, thiamine, A

Micro: Salmonella, Listeria, Enterobacteriaceae

Estimated cost: £300-500 at UKAS lab

6. QC Record Sheet¶

Batch ID: PILOT-001
Date: __
Operator: __
Fibre ingredient used: Pumpkin powder / Carrot fibre (circle one)

Temperature Log¶

Checkpoint	Time	Temp (°C)
Pre-grind (block core)
Post-grind
Post-mix
Into freezer

Weight Log¶

Item	Target (g)	Actual (g)
Main ingredients subtotal	9,280
Pack A (dry preblend)	700
Pack B (oils)	110
Total	10,000

Quality Checks¶

[ ] Temperature maintained ≤4°C throughout
[ ] Pack A dispersed (no clumps/gel pockets; bowl scraped as needed)
[ ] All units sealed/closed properly
[ ] All units labelled
[ ] Into freezer within 30 min of packing

7. Post-Pilot Actions¶

Retain 4-6 units as reference samples
Submit lab samples within 1 week
Record results against FEDIAF targets
Decision gate: FEDIAF compliant → proceed to co-packer

Document Control¶

Field	Value
Document Owner	Anton (Founder)
Version	1.1
Effective Date	February 2026
Classification	CONFIDENTIAL

Revision History¶

Version	Date	Changes
1.0	Jan 2026	Initial pilot protocol
1.1	Feb 2026	Aligned to GI-stable formulation: Dry Preblend corrected from 2.3% (230g) to 7.0% (700g); yeast reduced to 3.0%, added pumpkin/carrot fibre 2.0% + psyllium husk 0.5%, sunflower seed meal increased to 1.0%. Removed mixed tocopherols (conflicts with whole-food-only constraint). Corrected meat/organ percentages to match Production Master Spec v2.5 (skin 10.1%, tripe 4.3%, kidney/spleen 75/25 blend at 6.0%, liver 2.7%, trim 16.2%). Updated masterbatch step for 700g preblend (3.0 kg meat base, incremental addition, clump/gel-pocket check). Packing format made flexible (vacuum bags or rigid tubs). Updated QC targets to match corrected weights.