PROTOCOL RAW¶
Manufacturing Playbook¶
From Home Pilot to Co-Packer Launch
Version 1.1 | February 2026
CONFIDENTIAL
Document Pack Contents¶
This playbook consists of multiple integrated documents:
Document 1: Manufacturing Playbook (this document) Master overview, timeline, decision gates, and coordination guide
Document 2: Production Master Specification v2.4 Final formulation, ingredient matrix, Functional Preblend, processing sequence
Document 3: Supplier Specification Pack COA requirements for bone-in mince, CLO, oyster powder, mussel powder, kelp, pumpkin/carrot fibre, psyllium husk
Document 4: Co-Packer RFQ Package Capability checklist, technical requirements, commercial terms template
Document 5: Home Pilot Protocol 10kg trial batch procedure, equipment list, QC checkpoints
Document 6: Lab Validation Panel Lock-in nutritional assay requirements, ongoing pathogen testing protocol
Document 7: Packaging Specification Tray + MAP lidding film + linerless C-wrap label specification
1. Executive Summary¶
This playbook guides Protocol Raw from formulation validation through co-packer production launch. The path involves three distinct phases:
-
Home Pilot (Weeks 1–4): Validate formulation with 10kg trial batch, submit for full nutritional panel, confirm FEDIAF compliance, validate GI tolerance
-
Co-Packer Selection (Weeks 2–8): RFQ process, facility visits, capability assessment, contract negotiation
-
Production Launch (Weeks 8–12): First commercial batch, hold-and-release validation, customer shipments begin
Critical Success Factors¶
- Lab-verified FEDIAF Growth & Reproduction compliance before any commercial production
- COA-controlled anchor ingredients (kelp, oyster powder, mussel powder, CLO) with verified potency
- Co-packer capable of batch-dose Functional Preblend addition (lot-tracked) and validated dispersion (no psyllium clumping)
- Hold-and-release pathogen testing infrastructure from batch one (defined sampling + quarantine + release authorisation)
- COGS at or below £4.50/kg by Month 4 (Stop-Rule threshold)
2. Formulation Summary¶
2.1 Product Specification¶
| Parameter | Specification |
|---|---|
| Product Name | Protocol Raw Complete |
| FEDIAF Standard | All Life Stages (Growth & Reproduction) |
| Target Energy Density | ~1900 kcal/kg (target) |
| Protein (As Fed) | ~15% (target; confirm via validation) |
| Fat (As Fed) | ~16% (target; confirm via validation) |
| Pack Format | 500g thermoform rPET tray + MAP seal + linerless C-wrap label |
| Shelf Life (Frozen) | 12 months at -18°C |
2.2 Micronutrient Anchoring Strategy¶
The formulation achieves FEDIAF compliance without synthetic premix through strategic whole-food anchors and a COA adjustment protocol:
| Nutrient | Anchor | Inclusion | COA Required |
|---|---|---|---|
| Zinc | Oyster Powder | 0.35% | Zn mg/100g, Cd mg/kg |
| Manganese | Mussel Powder | 0.10% | Mn mg/100g |
| Iodine | Kelp Meal | 0.05% | Iodine mg/kg |
| Vitamin D | Cod Liver Oil (assayed) | 0.2% | Vit D IU/g (min), Vit A IU/g |
| EPA/DHA | Fish Oil | 0.8% | EPA %, DHA %, Peroxide value (PV) |
2.3 Stool Stability System (Whole-Food Fibre)¶
Target customer includes kibble-switching family pets and small breeds. To reduce loose-stool incidents at scale (without synthetic additives), the formulation includes a whole-food fibre system delivered via the Functional Preblend:
- Pumpkin powder or carrot fibre: 2.0% (finished-product inclusion target)
- Psyllium husk: 0.5% (finished-product inclusion target)
- Nutritional yeast: reduced vs prior versions (carrier/B-vitamin support, not dominant dry mass)
Operational note: Psyllium can clump if added incorrectly. Mixing sequence must use a meat masterbatch step to disperse the Functional Preblend uniformly before final mix.
3. Implementation Timeline¶
Phase 1: Home Pilot (Weeks 1–4)¶
- Week 1: Source pilot ingredients (10kg batch quantities)
- Week 1: Obtain COAs for anchor ingredients
- Week 2: Prepare Functional Preblend (dry + oil premixes)
- Week 2: Execute 10kg home pilot batch
- Week 2: Run GI tolerance transition test (7–10 day transition; stool scoring)
- Week 2: Submit composite sample to UKAS lab (full nutritional panel)
- Week 3–4: Receive lab results
- Week 4: DECISION GATE — Confirm FEDIAF compliance or reformulate
- Week 4: DECISION GATE — GI tolerance acceptable? If no → adjust fibre/fat variability levers and re-run
Phase 2: Co-Packer Selection (Weeks 2–8)¶
- Week 2–3: Issue RFQ to 4–6 UK raw pet food co-packers
- Week 4–5: Receive quotes, classify using capability checklist
- Week 5–6: Site visits to top 2–3 candidates
- Week 6–7: Negotiate terms, confirm Functional Preblend handling
- Week 8: DECISION GATE — Sign co-packer agreement
Phase 3: Production Launch (Weeks 8–12)¶
- Week 8–9: Source production-scale ingredients
- Week 9: Prepare Functional Preblend for first batch
- Week 9–10: Validate Functional Preblend dispersion (no psyllium clumping) during trial mix
- Week 10: First commercial batch (500–1000kg): grinds, mixes, adds preblend + oils, fills 500g trays, MAP-seals, labels, freezes
- Week 10: Submit pathogen samples (hold-and-release)
- Week 11: Receive lab clearance, release batch
- Week 12: First customer shipments
4. COGS Targets & Stop-Rules¶
| Phase | COGS Target | Volume |
|---|---|---|
| Pilot / Early Phase A | £4.10 – £4.90/kg | 1–10 t/month |
| Late Phase A | £3.70 – £4.50/kg | 10–20 t/month |
| Phase B | £3.20 – £4.00/kg | 20–50 t/month |
| Phase C–D | £2.60 – £3.40/kg | 50–100+ t/month |
Stop-Rule: Month 4 COGS Gate¶
If landed COGS exceeds £4.50/kg at Month 4: PAUSE SCALE
Required actions if Stop-Rule triggered:
- Renegotiate co-packer terms
- Confirm whether Test-and-Release admin fee is separately itemised
- Review formulation inputs for cost-neutral substitutions
- Consider holding price at top of band
5. Decision Gates¶
Gate 1: Formulation Lock (Week 4)¶
Criteria: Lab results confirm FEDIAF Growth & Reproduction compliance
- All micronutrients meet minimums per 1000 kcal
- Ca:P ratio within 1.0–2.0 range
- Vitamin D meets minimum (138 IU/1000 kcal)
- No nutrients exceed FEDIAF maximums
- GI tolerance gate passed (stool scoring on kibble→raw transition)
If FAIL: Adjust anchor dosing based on COA potency, re-run pilot batch
Gate 2: Co-Packer Selection (Week 8)¶
Criteria: Signed agreement with capable co-packer
- Passes all Must-Have capability checks
- Can handle Functional Preblend units (batch-dose addition, lot-tracked)
- Quarantine capacity for hold-and-release
- Quoted COGS within target range
If FAIL: Expand RFQ scope, consider formula modifications for compatibility
Gate 3: First Batch Release (Week 11)¶
Criteria: First commercial batch cleared for sale
- Pathogen tests: Salmonella NOT DETECTED, Listeria NOT DETECTED
- Enterobacteriaceae <100 cfu/g
- Packaging QA passed: seal integrity (MAP), label adhesion at -18°C, QR scan pass rate
- Mix QA passed: Functional Preblend dispersion confirmed (no clumps/gel pockets)
- QR code and proof portal functional
- Batch allocated to orders in system
If FAIL: Destroy batch, investigate root cause, re-run production
6. Supporting Documents¶
This playbook is supported by the following detailed specifications:
Production Master Specification v2.4¶
Complete formulation with:
- Full ingredient matrix (100kg batch and 10kg pilot)
- Functional Preblend compositions (dry pack + oil pack + fibre system)
- Processing sequence and grind specifications
- QC checkpoints
Supplier Specification Pack¶
Individual spec sheets for COA-controlled ingredients:
- Bone-in Chicken Mince: particle size, bone %, Ca/P
- Cod Liver Oil: Vitamin D IU/g (min 150), Vitamin A IU/g
- Oyster Powder: Zinc mg/100g, cadmium limits
- Mussel Powder: Manganese mg/100g
- Kelp Meal: Iodine mg/kg
- Pumpkin powder / carrot fibre: micro spec + contaminants
- Psyllium husk: micro spec + contaminants + gel quality/particle spec
Co-Packer RFQ Package¶
- Capability checklist (classify as: Run as written / Functional Preblend only / Needs change / Capacity mismatch)
- Technical requirements summary
- Site visit question list
- Commercial terms template
Home Pilot Protocol¶
- Equipment list and setup
- Step-by-step 10kg batch procedure
- Temperature and timing controls
- Sample collection for lab submission
- QC record sheet
Lab Validation Panel¶
- Lock-in validation: Full nutritional panel (proximate, minerals, vitamins, fatty acids)
- Ongoing pathogen panel: Salmonella, Listeria, Enterobacteriaceae
- Periodic audit panel: Iodine, Vitamin D, Ca/P (quarterly)
- Recommended UKAS-accredited labs
Packaging Specification¶
- 500g thermoform rPET tray specification
- MAP lidding film specification and gas mix
- Linerless C-wrap label specification
- Seal integrity testing protocol
- Cold-storage label adhesion requirements (-18°C)
Appendix: Document Control¶
| Field | Value |
|---|---|
| Document Owner | Anton (Founder) |
| Version | 1.1 |
| Last Updated | February 2026 |
| Classification | CONFIDENTIAL |
| Next Review | Post-pilot (Week 5) |
Revision History¶
| Version | Date | Changes |
|---|---|---|
| 1.0 | Jan 2026 | Initial release incorporating optimised formulation with COA-driven anchors, powder substitution for shellfish, CLO addition for Vitamin D |
| 1.1 | Feb 2026 | Updated pack format to tray/MAP/label; corrected anchor inclusions (mussel 0.10%, kelp 0.05%); added fibre stool-stability system (Section 2.3); updated gates for GI tolerance and dispersion; added Packaging Specification to supporting documents; global terminology update to Functional Preblend |