Protocol Raw Complete — Production Master Specification v2.7¶
Status: 🟡 PRODUCTION READY (pending validation gates — see Sections 1, 8.2)
Target Standard: FEDIAF All Life Stages (Growth & Reproduction)
Document ID: SPEC-PROD-v2.7
Last Updated: February 2026
Classification: CONFIDENTIAL
1. Product Overview¶
| Parameter | Specification |
|---|---|
| Product Name | Protocol Raw Complete |
| FEDIAF Standard | All Life Stages (Growth & Reproduction) |
| Target Energy Density | ~1900 kcal/kg (target pending validation) |
| Protein (As Fed) | ~15% (~42% DM) |
| Fat (As Fed) | ~16% |
| Pack Format | 500g thermoform rPET tray + MAP seal + linerless C-wrap label |
| Shelf Life | 12 months at −18°C |
| Species Declaration | Beef-led (49.1%) / Chicken (40.1%) |
2. Packaging Specification¶
2.1 Strategic Positioning¶
Protocol Raw packaging must signal system, not food brand.
The tray is instrumentation, not packaging.
| Attribute | Target | Avoid |
|---|---|---|
| Visual feel | Clinical, systematic | Friendly, lifestyle |
| Function | Lab sample label | Billboard |
| Goal | Say less, more clearly | Say more |
| Material choice | Mono-material, kerbside recyclable | Multi-layer laminate |
| Sustainability claim | Mechanically true or silent | Aspirational, soft |
| Customer signal | Commitment-first | Convenience-first |
| Support load | Self-evident | Requires explanation |
Non-negotiable rule: Never choose packaging that requires explanation.
2.2 Pack Format: Three-Component System¶
Protocol Raw uses the same proven format as Bella & Duke (thermoform + MAP + linerless label) but with opposite intent: they optimised to say more; we optimise to say less, more clearly.
┌─────────────────────────────────────────┐
│ 1. THERMOFORM rPET TRAY │
│ Clear, lightweight, recyclable │
└─────────────────────────────────────────┘
↓
┌─────────────────────────────────────────┐
│ 2. MAP SEAL (Lidding Film) │
│ Plain film, gas-flushed seal │
└─────────────────────────────────────────┘
↓
┌─────────────────────────────────────────┐
│ 3. LINERLESS C-WRAP LABEL │
│ All branding + batch info here │
└─────────────────────────────────────────┘
2.3 Component 1: Thermoform Tray¶
| Parameter | Specification |
|---|---|
| Format | Thermoformed tray (not pre-formed tub) |
| Material | rPET (recycled PET), mono-material |
| Recycled content | Minimum 50% post-consumer recycled |
| Colour | Clear (product visible) |
| Capacity | 500g nominal (±10g) |
| Target weight | ≤15g per tray (weight-efficient) |
| Temperature rating | Freezer-safe to −25°C minimum |
| Recyclability | Designed to be kerbside recyclable. OPRL position to be confirmed with supplier for exact tray + film + label combination before any on-pack claim is made. |
Reference: Bella & Duke achieved 13g/tray with thermoform vs 21g with tubs (38% reduction).
2.4 Component 2: MAP Seal (Lidding Film)¶
| Parameter | Specification |
|---|---|
| Format | Heat-sealed lidding film |
| Material | Mono-PET (must match rPET tray material for recyclability) |
| Atmosphere | MAP (Modified Atmosphere Packaging): 70/30 CO₂/N₂ |
| Plain/unprinted — branding on C-wrap label, not film | |
| Peel | Clean peel, no sharding |
| Seal integrity | Tamper-evident, leak-proof |
| MAP headspace | Target 30–40% of tray volume. Headspace ratio affects gas exchange effectiveness, seal aesthetics, and pack rigidity post-freeze. Validate during first sealed trial trays — adjust fill weight or tray depth if headspace falls outside range. Note: headspace becomes critical if HPP (high pressure processing) is ever trialled. |
2.5 Component 3: Linerless C-Wrap Label¶
| Parameter | Specification |
|---|---|
| Format | Linerless label, C-wrap application (wraps around tray) |
| Print surface | Front face; reverse available for regulatory text |
| Application | Machine-applied at 100+ packs/min (Phase B co-packer); hand-applied or semi-auto at Phase A volumes |
| Adhesive | Freezer-grade, no lift at −18°C |
| Variable data | Batch ID, BB date, QR code per production run |
Reference suppliers: - Label printer: Reflex Labels (reflexlabels.co.uk) - Label applicator: Ravenwood Nobac 5000 (ravenwood.co.uk) — Phase B; manual application at Phase A volumes
2.6 Label Content Philosophy¶
The label is a lab sample label, not a billboard.
We use linerless labels for manufacturing efficiency, not marketing surface.
What MUST appear (required):¶
| Element | Specification |
|---|---|
| Protocol Raw logo | Minimal, functional |
| Product name | "Protocol Raw Complete" |
| Weight | "500g" |
| QR code | Minimum 25mm, high contrast, "Scan for Batch Report" |
| Batch ID | Human-readable, minimum 10pt |
| Best before | Format: BB DD/MM/YY |
| FEDIAF statement | "Complete pet food for dogs — All Life Stages" |
| Composition | Per Section 8.1 |
| Analytical constituents | Per Section 8.2 |
| Feeding guide | Minimal on-pack statement: "Feed 2–3% of body weight daily, adjusted for activity. See protocolraw.com/feeding for your dog's precise amount." |
| Allergen declaration | "Contains: Fish, Eggs, Molluscs" |
| Storage instruction | "Store frozen at −18°C or below" |
| Company details | Name, address, contact |
| OPRL symbol | Per confirmed OPRL position for exact components (do not print "Widely Recycled" until supplier-backed confirmation) |
What is BANNED (never include):¶
- Recipe names or flavour variants
- Marketing copy or taglines beyond "Proof, Not Promises" (if used at all)
- Lifestyle imagery (dogs, families, bowls)
- Emotional language ("love", "happy", "healthy")
- Sustainability marketing ("eco", "planet-friendly", "green")
- Healthcare advice or wellness claims
- Promotions or offers
- Excessive colour or visual noise
- Anything that requires explanation
Maximum words rule:¶
Front face of label: ≤50 words (excluding legally required text)
If it doesn't fit in 50 words, it doesn't belong on the pack.
2.7 Visual Design Principles¶
| Principle | Implementation |
|---|---|
| Colour palette | Monochrome or maximum 2 colours + black |
| Typography | Clean, sans-serif, high legibility |
| White space | Generous — emptiness signals confidence |
| Hierarchy | QR code and Batch ID visually dominant |
| Contrast | High contrast for freezer/low-light scanning |
The pack should feel closer to medical packaging than pet food packaging.
2.8 Why This Format¶
What we copy from Bella & Duke (mechanical): - Thermoformed trays (weight-efficient, fast sealing) - Linerless C-wrap labels (efficient, zero liner waste) - MAP sealing (standard, proven) - High-speed proven format
What we reject from Bella & Duke (philosophical): - Marketing use of label real estate - Recipe differentiation on-pack - Emotional copy - Visual warmth doing trust's job
Why NOT flexible pouches (Butternut-style): - Not kerbside recyclable in UK - Undermines "proof, not promises" positioning - Collapses brand into "fresh DTC food" category - QR codes distort on flexible surfaces - Creates FAQ debt and support load
2.9 Future Format (Phase C+)¶
Frozen brick/block format remains strategic north star for category leadership phase: - Maximum "system, not food" signal - Best proof surface geometry - Zero lifestyle cosplay - Requires established customer trust before introduction
Decision to transition will be evaluated at 10k+ customers.
2.10 Supplier Requirements¶
Tray supplier must provide:
| Requirement | Detail |
|---|---|
| Material certification | Mono-material rPET declaration |
| Recycled content | Minimum 50% PCR certification |
| Food contact compliance | EU 1935/2004 / UK equivalent |
| Recyclability confirmation | Supplier to provide OPRL-eligible position for tray + lidding film + label as a system. Do not claim "Widely Recycled" without component-level confirmation that linerless adhesive does not contaminate the PET recycling stream. |
| Temperature performance | Freeze-thaw stability data to −25°C |
| Dimensional consistency | ±1mm tolerance |
| MOQ and lead time | Phase A volumes (~2,000–5,000 units/month) |
Lidding film supplier must provide:
| Requirement | Detail |
|---|---|
| Material certification | Mono-PET (match rPET tray for single-stream recyclability) |
| Seal performance | Clean peel, tamper-evident |
| Temperature performance | Freezer-grade to −25°C |
| Compatibility | Confirmed for tray material and sealing equipment (Proseal TT-G at Phase A; co-packer equipment at Phase B) |
Label supplier must provide:
| Requirement | Detail |
|---|---|
| Format | Linerless, C-wrap compatible |
| Variable data capability | Batch codes, dates, QR codes per run |
| Adhesive performance | Freezer-grade, no lift at −18°C |
| Print durability | Smudge-proof, moisture-resistant |
| QR verification | Scan-test confirmation per batch |
| MOQ | Phase A volumes |
Reference contacts: - Reflex Labels: reflexlabels.co.uk (Bella & Duke's label supplier) - Ravenwood Packaging: ravenwood.co.uk (linerless applicator equipment)
2.11 Cost Estimate (Phase A)¶
| Component | Estimated Unit Cost | Notes |
|---|---|---|
| Thermoform rPET tray | £0.12–0.18 | Lighter than pre-formed tubs |
| MAP lidding film | £0.03–0.05 | Plain, unprinted |
| Linerless C-wrap label | £0.08–0.12 | Variable data included |
| Total primary pack | £0.23–0.35 | Per 500g unit |
Budget £0.30/unit for planning. Validate with supplier quotes.
Note: Bella & Duke achieved 98% reduction in label shipping costs with linerless vs traditional self-adhesive labels.
3. Supply Chain Model¶
3.1 Two-Phase Manufacturing Strategy¶
Protocol Raw's manufacturing strategy follows two phases, as defined in Manufacturing Playbook v2.0:
Phase A (Months 0–6): Self-Manufacture. Founder-operated APHA-approved facility. Protocol Raw sources meat/organ ingredients directly, receives Functional Preblend units from a blender/packer, and performs the production process (grind, mix, fill, seal, freeze). This maintains full production control during validation while outsourcing micro-ingredient complexity to a specialist.
Phase B (Months 7+): Co-Packer Production. Following seed close, production transitions to a co-packer. The three-party supply chain model (Protocol Raw + Blender/Packer + Co-Packer) applies from Phase B onwards.
The formulation, processing sequence, packaging format, and quality standards are identical in both phases. The only difference is who operates the production equipment.
3.2 Phase A Supply Chain (Self-Manufacture)¶
┌──────────────────────────────────────────────────────────────┐
│ BLENDER/PACKER │
│ • Sources anchor ingredients (kelp, oyster, mussel, CLO) │
│ • Blends Functional Preblend to Protocol Raw spec │
│ • Ships batch-dose preblend units to founder facility │
└──────────────────────────────────┬───────────────────────────┘
│
▼
┌──────────────────────────────────────────────────────────────┐
│ PROTOCOL RAW (Founder-Operated Facility) │
│ • Sources meat/organ ingredients directly │
│ • Receives preblend units from blender/packer │
│ • Holds preblend inventory │
│ • Performs full production: grind, mix, fill, seal, freeze │
│ • Supplies own packaging (trays + labels) │
│ • Holds for lab release, dispatches to customers │
└──────────────────────────────────────────────────────────────┘
Phase A ingredient sourcing:
| Component | % | Sourced By | Notes |
|---|---|---|---|
| Meat & Organs | 89.2% | Protocol Raw | Wholesale/small-batch from APHA-registered suppliers |
| Eggs | 2.7% | Protocol Raw | Pasteurised liquid or fresh |
| Fish Oil + Flaxseed Oil | 0.9% | Protocol Raw | Commodity spec |
| Dry Functional Pack (Functional Preblend) | 7.0% | Blender/packer | Batch-dose units shipped to founder facility |
| Oil Pack (CLO) | 0.2% | Blender/packer | Batch-dose bottles shipped to founder facility |
| Packaging | — | Protocol Raw | Trays + labels |
Why use a blender from Phase A (not in-house preparation): - COA-controlled anchors (kelp, oyster, mussel, CLO) require verified potency to hit FEDIAF compliance - Weighing 50g of kelp powder on precision scales every batch introduces dosing error risk - Blender handles ingredient sourcing, COA verification, and lot tracking - Founder receives pre-weighed units — just add one per batch - Consistent quality from batch to batch - Same supply chain model as Phase B, just different delivery address
3.3 Phase B Supply Chain (Co-Packer Production)¶
┌──────────────────────────────────────────────────────────────┐
│ PROTOCOL RAW │
│ • Sets specifications │
│ • Approves COAs │
│ • Manages relationships │
│ • Supplies packaging (trays + labels) │
└──────────────────────────────┬───────────────────────────────┘
│
┌───────────────────┴───────────────┐
▼ ▼
┌─────────────────────────┐ ┌─────────────────────────┐
│ BLENDER/PACKER │ │ CO-PACKER │
│ • Sources anchors │ │ • Sources meats, eggs │
│ • Blends Dry Pack │ │ • Sources commodity │
│ (Functional Preblend)│ │ oils (fish, flax) │
│ • Bottles Oil Pack │────▶│ • Adds preblend units │
│ • Ships preblend units │ │ at mix stage │
│ to co-packer │ │ • Grinds, fills trays, │
└─────────────────────────┘ │ seals, labels, │
│ freezes │
└─────────────────────────┘
Phase B ingredient sourcing:
| Component | % | Supplied By | Notes |
|---|---|---|---|
| Meat & Organs | 89.2% | Co-packer | See Section 4.1 |
| Eggs | 2.7% | Co-packer | Pasteurised liquid or fresh |
| Fish Oil + Flaxseed Oil | 0.9% | Co-packer | Commodity spec |
| Dry Functional Pack (Functional Preblend) | 7.0% | Blender/packer | Pre-measured preblend unit (bag/drum/tote; lot-tracked) |
| Oil Pack (CLO) | 0.2% | Blender/packer | Pre-made bottle |
| Packaging | — | Protocol Raw | Trays + labels supplied to co-packer |
| TOTAL | 100% |
3.4 Why This Model?¶
The Dry Functional Pack contains COA-controlled anchor ingredients (kelp, oyster, mussel) and a whole-food fibre system (pumpkin/carrot fibre + psyllium) that must be verified for potency and quality to ensure FEDIAF compliance and stool stability. The Oil Pack contains assayed cod liver oil for vitamin D.
Both phases (blender/packer from day one): By having a specialist blender/packer produce batch-dose preblend units: - You control the critical specs without becoming a micro-ingredient operation - No precision scales or micro-dosing required at the production facility - The production operator (founder in Phase A, co-packer in Phase B) just "adds the preblend unit" - Lot traceability is clean: one preblend lot number per batch - Consistent quality — blender handles COA verification and potency adjustments - Same supply chain in both phases (only the delivery address changes)
Both phases: By supplying your own packaging: - You control brand presentation and proof system visibility - You can switch manufacturers without redesigning packaging - Consistent customer experience regardless of production origin
4. Final Ingredient Matrix¶
4.1 Meats & Organs¶
| Class | Ingredient | % | Per 1,000 kg Batch | Role/Note |
|---|---|---|---|---|
| Bone Base | Bone-in Chicken Mince | 23.0% | 230.0 kg | Primary Ca:P; 3–5mm particle, 8–12% bone |
| Red Meat | Beef Heart | 19.9% | 199.0 kg | Lean protein, colour, taurine |
| Red Meat/Fat | Beef Trim (60/40) | 16.2% | 162.0 kg | Key energy driver |
| Fat Source | Chicken Skin (fat-on) | 10.1% | 101.0 kg | Energy, palatability |
| Texture | Chicken Gizzards | 7.0% | 70.0 kg | Structure, chew |
| Volume/Gut | Green Beef Tripe | 4.3% | 43.0 kg | Digestive enzymes |
| Organs | Beef Kidney/Spleen (75/25) | 6.0% | 60.0 kg | Micronutrient support |
| Organs | Beef Liver | 2.7% | 27.0 kg | Vitamin A + Copper |
| SUBTOTAL | 89.2% | 892.0 kg |
4.2 Eggs & Commodity Oils¶
| Ingredient | % | Per 1,000 kg Batch | Spec |
|---|---|---|---|
| Pasteurised Whole Egg | 2.7% | 27.0 kg | Liquid or fresh |
| Fish Oil (Salmon/Sardine) | 0.8% | 8.0 kg | EPA+DHA ≥25%, peroxide <5 |
| Flaxseed Oil | 0.1% | 1.0 kg | Food/feed grade |
| SUBTOTAL | 3.6% | 36.0 kg |
4.3 Dry Functional Pack (Functional Preblend)¶
Both Phase A and Phase B: Supplied by blender/packer as batch-dose preblend kit (total 70.0 kg per 1,000 kg finished batch), labelled with a single lot number. For handling, the kit may contain multiple sealed inner bags; all contents must be added.
| Ingredient | % of Finished Product | Per 1,000 kg Batch | Function |
|---|---|---|---|
| Nutritional Yeast | 3.0% | 30.0 kg | Carrier + B-vitamin support |
| Pumpkin Powder or Carrot Fibre | 2.0% | 20.0 kg | Stool stability (gentle fibre) |
| Sunflower Seed Meal | 1.0% | 10.0 kg | Linoleic acid + carrier mass |
| Psyllium Husk | 0.5% | 5.0 kg | Stool normaliser (gel-forming soluble fibre) |
| Oyster Powder | 0.35% | 3.5 kg | Zinc anchor |
| Mussel Powder | 0.10% | 1.0 kg | Manganese anchor |
| Kelp Meal | 0.05% | 0.5 kg | Iodine anchor |
| PACK TOTAL | 7.0% | 70.0 kg |
Note: The Functional Pack includes a whole-food fibre system (pumpkin/carrot fibre + psyllium) to improve stool consistency during kibble→raw transitions, while maintaining a whole-food, no-synthetic-premix formulation.
4.4 Oil Pack¶
Both Phase A and Phase B: Supplied by blender/packer as one sealed bottle per batch, labelled with lot number.
| Ingredient | % of Finished Product | Per 1,000 kg Batch | Function |
|---|---|---|---|
| Cod Liver Oil (Assayed) | 0.2% | 2.0 kg | Vitamin D anchor |
| PACK TOTAL | 0.2% | 2.0 kg |
Critical: CLO must have Vitamin D ≥150 IU/g per COA.
4.5 Batch Size Summary¶
| Batch Size | Meats/Organs | Eggs/Oils | Dry Pack Preblend | Oil Pack | Trays Produced |
|---|---|---|---|---|---|
| 500 kg | 446.0 kg | 18.0 kg | 35.0 kg | 1.0 kg | ~1,000 trays |
| 1,000 kg | 892.0 kg | 36.0 kg | 70.0 kg | 2.0 kg | ~2,000 trays |
| 2,500 kg | 2,230.0 kg | 90.0 kg | 175.0 kg | 5.0 kg | ~5,000 trays |
5. Nutritional Targets¶
5.1 Macronutrients¶
| Parameter | Target | FEDIAF Min (Growth) |
|---|---|---|
| Energy Density | ~1900 kcal/kg (target; confirm by validation) | ≥1580 kcal/kg |
| Protein (DM) | ~42% | ≥25% |
| Fat (DM) | ~40% | ≥8.5% |
5.2 Critical Micronutrients (Per 1000 kcal)¶
| Nutrient | Target | FEDIAF Min | Anchor Source |
|---|---|---|---|
| Calcium | ~2.5 g | 1.0 g | Bone-in mince |
| Phosphorus | ~2.0 g | 0.9 g | Bone-in mince |
| Ca:P Ratio | 1.2–1.4:1 | 1.0–2.0:1 | — |
| Zinc | ≥28 mg | 18.3 mg | Oyster powder (Dry Pack) |
| Manganese | ≥1.5 mg | 1.13 mg | Mussel powder (Dry Pack) |
| Iodine | ≥350 µg | 350 µg | Kelp meal (Dry Pack) |
| Vitamin D | ≥138 IU | 138 IU | Cod liver oil (Oil Pack) |
| EPA + DHA | ≥0.13 g | 0.13 g | Fish oil |
| Linoleic Acid | ≥3.3 g | 3.25 g | Sunflower + skin |
6. Processing Specification¶
6.1 Overview¶
This processing specification applies identically to both Phase A (self-manufacture) and Phase B (co-packer). The manufacturer:
- Grinds meats and organs
- Creates a masterbatch with the Dry Functional Pack preblend
- Mixes everything together with eggs and oils
- Portions into 500g trays
- MAP-seals trays (70/30 CO₂/N₂)
- Applies batch-specific labels
- Blast freezes and holds for lab clearance
Phase A note: At self-manufacture volumes, the founder performs all steps. See Manufacturing Playbook v2.0, Section 8 for the full self-manufacture production workflow including weekly cadence and labour planning.
Phase B note: The co-packer receives preblend units from the blender/packer and packaging from Protocol Raw. The co-packer follows this specification exactly.
6.2 Processing Sequence¶
Step 1: Ingredient Preparation¶
- Temper frozen meats to −2°C to 0°C core temperature
- Maintain cold chain throughout (<4°C ambient)
- Verify Dry Functional Pack preblend (received from blender/packer; check lot number, sealed, within date)
- Verify Oil Pack (received from blender/packer; check lot number, sealed, within date)
- Record all lot numbers (preblend, oil pack, meat/organ lots)
- Verify packaging stock (trays + labels)
Step 2: Grind Beef and Eggs¶
- Single-pass grind at 8-10mm plate
- Grind beef cuts/organs only: heart, trim, tripe, kidney/spleen, liver, eggs
- Poultry (pre-ground from supplier) is NOT ground in-house — added directly at the mixer stage
- Target: uniform mince with no large chunks
Step 3: Create Masterbatch (Critical for Fibre Dispersion)¶
The masterbatch step disperses the Functional Preblend uniformly into a portion of the ground meat before the main mix. This prevents psyllium clumping and ensures even distribution of anchor ingredients.
Masterbatch ratio: Use 25–40% of the total batch mass as the masterbatch base. The full Dry Functional Pack preblend (7% of batch mass) is added to this base.
| Batch Size | Masterbatch meat (25–40%) | Preblend added | Total masterbatch |
|---|---|---|---|
| 500 kg | 125–200 kg | 35.0 kg | 160–235 kg |
| 1,000 kg | 250–400 kg | 70.0 kg | 320–470 kg |
Phase A (self-manufacture): At 500 kg batches with a 200L mixer, use ~100–150 kg of ground meat as masterbatch base + 35 kg preblend. This may require 2 masterbatch sub-runs if mixer working capacity is limited. Each sub-run receives a proportional share of the preblend. Record sub-run splits.
Phase B (co-packer): At 1,000 kg+ batches, the masterbatch is typically a single run using a larger mixer (300–400 kg meat + 70 kg preblend).
Procedure: 1. Transfer the calculated quantity of ground meat to mixer 2. Start mixer and add the Dry Functional Pack preblend in 2–4 increments, allowing each increment to incorporate before the next 3. Mix for 6–10 minutes (or per validated SOP) until powder is evenly distributed with no visible clumps/gel pockets (psyllium control) 4. QC check: inspect mixer walls/paddles and product for build-up or clumps; scrape down if required 5. Acceptance criteria: no visible clumps, gel pockets, or dry powder pockets. If any are found, continue mixing in 2-minute increments until clear or discard and re-run if dispersion cannot be achieved.
Step 4: Main Mix¶
- Add remaining ground meats to mixer
- Add masterbatch
- Prepare egg/oil mixture:
- Beat eggs (or use liquid egg)
- Add fish oil and flaxseed oil
- Add entire contents of Oil Pack (CLO)
- Stir to combine
- Add egg/oil mixture to mixer
- Mix until uniform (typically 4–6 minutes)
- Monitor temperature — do not exceed 4°C
Step 5: Portion & Pack¶
- Fill trays to 500g ±10g
- MAP seal with 70/30 CO₂/N₂ gas mix
- Verify seal integrity (no gaps, tamper-evident, leak-proof)
- Apply batch-specific linerless C-wrap label (QR code, batch ID, dates)
- Verify QR code scans correctly (spot check)
Step 6: Freeze & Hold¶
- Blast freeze to −18°C core
- Transfer to quarantine storage (HOLD area) — physically segregated from released stock
- Batch remains in HOLD until Protocol Raw confirms lab clearance
7. QC Checkpoints¶
These checkpoints apply to both Phase A (self-manufacture) and Phase B (co-packer) production environments.
7.1 Pre-Production¶
| Check | Acceptance Criteria | Record |
|---|---|---|
| Functional Pack preblend verified | Sealed, labelled, within date, lot number recorded | Lot number |
| Oil Pack verified | Sealed, labelled, within date, lot number recorded | Lot number |
| Meat ingredient lots recorded | All lots documented | Lot numbers |
| Packaging received/verified | Trays + labels correct count | Delivery note / stock count |
| Equipment sanitised | Visual clean + sanitiser log | Sign-off |
| Processing area temperature | ≤12°C | Temp reading |
7.2 During Production¶
| Check | Acceptance Criteria | Record |
|---|---|---|
| Tempering temperature | −2°C to 0°C core | Temp reading |
| Mix temperature | ≤4°C throughout | Temp reading |
| Preblend fully added | All preblend contents added; added in increments | Operator initials |
| Clump check (fibre dispersion) | No visible clumps/gel pockets; walls inspected | Pass/fail |
| Oil Pack fully added | Visual check — bottle/container empty | Operator initials |
| Tray fill weight | 500g ±10g | Sample weights |
| MAP seal integrity | Tamper-evident, leak-proof, gas retention | Visual check + leak test |
| Label applied correctly | Flat, no bubbles, QR readable, correct batch data | Visual check |
| QR scan test | Successful scan (spot check 1 in 50) | Pass/fail |
7.3 Post-Production¶
| Check | Acceptance Criteria | Record |
|---|---|---|
| Core temp post-freeze | ≤−18°C | Temp reading |
| Label accuracy | Batch code, dates, QR correct | Visual check |
| Sample collected | Composite from 6–10 trays | Sample ID |
| Batch moved to HOLD | Segregated from released stock | Location |
| Batch record complete | All fields populated, operator signed | Sign-off |
8. Label Declaration¶
8.1 Composition Statement¶
Chicken (bone-in mince 23%, skin 10.1%, gizzards 7%) 40.1%, Beef (heart 19.9%, trim 16.2%, tripe 4.3%, kidney & spleen 6%, liver 2.7%) 49.1%, nutritional yeast 3.0%, pumpkin powder or carrot fibre 2.0%, whole egg 2.7%, fish oil 0.8%, sunflower seed meal 1.0%, psyllium husk 0.5%, oyster powder 0.35%, cod liver oil 0.2%, mussel powder 0.1%, flaxseed oil 0.1%, kelp meal 0.05%.
8.2 Analytical Constituents¶
| Parameter | Declaration |
|---|---|
| Protein | 15% |
| Fat | 16% |
| Crude Fibre | TBD |
| Ash | 5% |
| Moisture | 62% |
⚠️ GATE: All analytical constituent values above are targets pending lock-in validation. Replace with validated lab results from the Home Pilot nutritional panel before first commercial label print run. Do not print labels with unvalidated values. Crude fibre is expected to be higher than typical raw formulations due to the whole-food fibre system (pumpkin/carrot + psyllium).
8.3 Allergen Declaration¶
Contains: Fish, Eggs, Molluscs
9. Batch Documentation¶
9.1 Required Records Per Batch¶
| Record | Completed By | Retained By |
|---|---|---|
| Batch Production Record (temps, weights, times) | Manufacturer | Both (Protocol Raw + Manufacturer) |
| Functional Pack preblend lot number | Manufacturer | Both |
| Oil Pack lot number | Manufacturer | Both |
| Meat/egg/oil ingredient lot numbers | Manufacturer | Both |
| Packaging lot numbers (trays, labels) | Manufacturer | Both |
| QC checklist (signed) | Manufacturer | Both |
| Lab submission record | Protocol Raw | Protocol Raw |
| Release decision | Protocol Raw | Protocol Raw |
| Labour hours (total production time) | Manufacturer | Protocol Raw |
"Manufacturer" = founder (Phase A) or co-packer (Phase B).
9.2 Traceability Chain¶
Kelp lot → Oyster lot → Mussel lot → Pumpkin/Carrot lot → Psyllium lot → CLO lot
↓
Dry Pack preblend lot + Oil Pack lot
↓
Production batch code
↓
Finished tray (QR code)
↓
Customer order
This traceability chain is manufacturer-agnostic. The batch ID format, QR mapping, and proof portal integration work identically regardless of whether the batch was produced in the self-manufacture facility (Phase A) or by a co-packer (Phase B). This is by design — the co-packer transition should be invisible to customers and to the proof portal.
9.3 Retention¶
- Batch records: Shelf life + 2 years (minimum 3 years)
- Retain samples: −18°C for shelf life duration
10. Formulation Adjustment Protocol¶
10.1 When Adjustments Happen¶
If anchor ingredient COAs show materially different potency, the preblend formula is adjusted before production — not the production process.
Phase A: The founder adjusts the preblend formula directly based on COA data.
Phase B: The blender/packer adjusts the preblend formula before production — not the co-packer.
Example: Kelp lot shows 750 mg/kg iodine instead of nominal 1000 mg/kg - Increase kelp in that preblend batch by factor of 1000/750 = 1.33 - Record the adjustment with rationale - Production process is unchanged — the manufacturer still adds "one preblend unit"
10.2 Founder's Role¶
Phase A: 1. Review COAs when received from suppliers 2. Approve or reject lots 3. Calculate any adjustment to preblend formula 4. Prepare adjusted preblend 5. Record all adjustments and rationale
Phase B: 1. Review COAs when blender/packer submits them 2. Approve or reject lots 3. Approve any adjustment calculations 4. You don't do the physical adjusting
11. Supplier Specifications Summary¶
11.1 Meat, Eggs, Commodity Oils¶
Phase A: Sourced directly by Protocol Raw from APHA-registered wholesalers/suppliers. Phase B: Sourced by co-packer.
| Ingredient | Critical Spec | COA Fields |
|---|---|---|
| Bone-in Chicken Mince | 3–5mm particle, 8–12% bone | Ca %, P %, Ash % |
| Fish Oil | EPA+DHA ≥25%, peroxide <5 | EPA %, DHA %, PV |
| Other meats/organs | Human chain or Cat 3, UK origin | Supplier cert |
11.2 Anchors + Fibre (Functional Preblend Ingredients)¶
Phase A: Sourced by Protocol Raw directly. Phase B: Sourced by blender/packer.
| Ingredient | Critical Spec | COA Fields |
|---|---|---|
| Kelp Meal | I 800–1200 mg/kg | Iodine mg/kg |
| Oyster Powder | Zn ≥500 mg/100g, Cd <1 mg/kg | Zn, Cd |
| Mussel Powder | Mn ≥10 mg/100g | Mn mg/100g |
| Cod Liver Oil | Vit D ≥150 IU/g | Vit D IU/g, Vit A IU/g |
| Pumpkin Powder / Carrot Fibre | Micro spec + contaminants (as defined) | TPC, Enterobacteriaceae, Salmonella (ND), moisture, foreign body control |
| Psyllium Husk | Micro spec + contaminants + physical spec | TPC, Enterobacteriaceae, Salmonella (ND), moisture, particle size/flow |
11.3 Packaging¶
| Component | Critical Spec | Supplier Requirements |
|---|---|---|
| Rigid tray | 500g, mono-material (rPET), freezer-safe to −25°C | Food contact compliance, OPRL position to be confirmed |
| MAP lidding film | Mono-PET, compatible with rPET tray and sealing equipment | Clean peel, tamper-evident, freezer-grade |
| Linerless C-wrap labels | Freezer-grade adhesive, variable data | QR verification, smudge-proof |
See Supplier Spec Pack for full details.
12. Self-Manufacture Equipment Reference¶
For Phase A self-manufacture, the following equipment is specified. Full detail including supplier references, budget ranges, and upgrade paths is documented in Manufacturing Playbook v2.0, Section 6.
| Equipment | Key Specification |
|---|---|
| MAP Tray Sealer | Proseal TT-G (benchtop, gas flush MAP, 4 cycles/min MAP mode) |
| Meat Grinder | Commercial, 8-10mm plate, boneless only (beef/organs). Poultry arrives pre-ground from supplier. |
| Mixer | Commercial paddle, 200L capacity |
| Blast Freezer | 200–500 kg/cycle, target −18°C core |
| Frozen Storage | Walk-in or chest, −18°C, capacity for HOLD + released stock |
| MAP Gas | Pre-mixed 70/30 CO₂/N₂ cylinders (BOC Food Fresh) |
| Scales | Bench scales for bulk ingredients (0–50 kg, ±10g); precision scales not required for routine production (preblend units arrive pre-weighed from blender) |
Upgrade path: If self-manufacture extends beyond planned Phase A window, the Proseal TT-G can be upgraded to the Proseal GTR (semi-automatic, 15–30 MAP cycles/min) within the same tooling ecosystem. All other equipment is co-packer-grade and would remain in use or be sold at Phase B transition.
Document Control¶
| Field | Value |
|---|---|
| Document Owner | Anton (Founder) |
| Version | 2.8 |
| Effective Date | April 2026 |
| Next Review | Post lock-in validation |
| Classification | CONFIDENTIAL |
Revision History¶
| Version | Date | Changes |
|---|---|---|
| 1.0 | Nov 2025 | Initial formulation with fresh oyster/mussel |
| 2.0 | Jan 2026 | Optimised: powders, CLO, bone-in mince, Functional Pack concept |
| 2.1 | Jan 2026 | Reframed for sachet model |
| 2.2 | Jan 2026 | Packaging format change to compostable tray + sleeve |
| 2.3 | Jan 2026 | Strategic packaging reset: Rigid mono-material tray selected for proof alignment and sustainability defensibility |
| 2.4 | Jan 2026 | Final packaging format locked: Thermoform rPET tray + MAP seal + linerless C-wrap label. Three-component system based on Bella & Duke mechanical approach but with opposite intent. Added label content philosophy, maximum 50-word rule, explicit banned elements list, visual design principles. Referenced Reflex Labels and Ravenwood as suppliers. Reduced cost estimate to £0.23–0.35/unit. |
| 2.5 | Feb 2026 | Reformulated Functional Pack for GI stability (yeast reduced 6%→3%; added pumpkin/carrot fibre 2.0% + psyllium husk 0.5%; sunflower seed meal increased to 1.0%); adjusted trim 15.5%→16.2% / tripe 5.0%→4.3% to maintain ~1900 kcal/kg target; updated processing Step 3 for fibre dispersion (300 kg masterbatch, incremental preblend addition, 6–10 min mix, clump QC check); preblend supplied as batch-dose kit (70 kg/1,000 kg batch, multiple inner bags); updated QC tables; updated composition statement + crude fibre to TBD; added pumpkin/carrot fibre + psyllium to supplier specs; global terminology update sachet→preblend kit. |
| 2.6 | Feb 2026 | Two-phase manufacturing model + spec corrections. Added Phase A self-manufacture alongside Phase B co-packer. Section 3 restructured for both supply chain models. Sections 6, 7, 9, 10, 11 updated to manufacturer-agnostic language. Added Section 12 (Self-Manufacture Equipment Reference). Corrections: Species declaration fixed from 51.9% to 49.1% beef (matching actual ingredient matrix). Masterbatch step rewritten as ratio-based SOP with Phase A mixer compatibility (sub-runs if needed). Lidding film locked to mono-PET (PP option removed). Recyclability claims tightened — OPRL "Widely Recycled" gated on supplier-backed component-level confirmation including linerless adhesive impact on PET stream. On-pack feeding guide added (minimal statement + URL). Analytical constituents gated on lock-in validation (do not print until lab-confirmed). Energy density marked as target pending validation. MAP headspace target added (30–40% tray volume). Status changed to 🟡 pending validation gates. |
| 2.7 | Feb 2026 | Blender/packer supply from Phase A. Corrected supply chain model: Functional Preblend and Oil Pack are supplied by blender/packer from day one (Phase A), not prepared in-house. Founder receives batch-dose units and adds one per batch — no precision scales or micro-dosing at production facility. Sections 3.1, 3.2, 3.4, 4.3, 4.4, 6.2 updated to reflect this. Rationale: COA-controlled anchors require verified potency; in-house weighing introduces dosing error risk; blender handles complexity while founder focuses on production. Same supply chain model in both phases — only the delivery address changes at Phase B. |
| 2.8 | Apr 2026 | Poultry format decision locked — pre-ground from supplier. Grinder spec updated to boneless (beef/organs only). Grind sequence updated to exclude poultry. Section 12 equipment reference updated. |