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Fresh Creations

About the company
Sainsbury's is the longest standing major food retailer in the UK, founded in 1869. The original stores were counter service but, as the supermarket self-service style arrived from the USA, Sainsbury's changed format to keep up with the times. It now has 405 stores nationwide serving 9 million customers per week. Large Sainsbury's superstores carry over 23,000 products, 40% of which are their own label.

In 1996, Sainsbury's employed a team of specialists to create a department of food excellence and innovation called the Food Centre. Here they develop their own label products, in-store leaflets, on-pack recipes and undertake quality and sensory testing. Historically, own label product development was led by suppliers. They presented their ideas to Sainsbury's buyers who adopted or rejected them. In addition, they now employ development chefs to work with the buyers, bringing specialist expertise to the development process. The team of product development and marketing specialists work together to consider the best ways to promote, enhance and develop products within every sector of the store. For more information about the work of new product development at Sainsbury's, click here.

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About the product
In 1997, Development Chef Stephen Parkins joined Sainsbury's with a brief to create innovative food and fresh ideas. Stephen had worked as a chef at the Sugar Club in London's Notting Hill, famous for its use of unusual ingredients and flavours, inspired by the cuisine of New Zealand, South East Asia and Europe.

He felt there was a niche for a do-it-yourself 'meal kit'. This would be a meal that was sold partly prepared, but would have the 'fresh-cooked' taste that is often missing from ready meals. The preparation would need to be completed by the consumer, but would be quick and simple to do.

The idea needed a further trigger and this came from the Sainsbury's fish department who knew from research that consumers below the age of 35 were not regular purchasers of fish. They were happy to choose fish from a restaurant or take-away menu, but less able or willing to prepare it at home.

Stephen was asked to come up with some fishy ideas that would appeal to this younger, affluent market. There were already plenty of prepared fish products on sale, so it needed to be something more unusual and original. The 'meal kit' idea seemed a perfect solution. Sainsbury's had been criticised in the trade press for copying, rather than leading, innovations in the chilled food sector and wanted to do something to improve this image. One of the unique selling points of this product would be its closeness in taste, quality, appearance and texture to the original dishes prepared by the development chef. This attention to detail in the development of the range was carried out by a team at Hazelwood Foods who manufacture the product for Sainsbury's.

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About the design and development process

Development work on the 'meal kits' that became Fresh Creations started in October 1997 with presentations to buyers to decide which recipes would form the core range.

The format for each product in the range would be:

  • a raw protein element which was seasoned, marinated or coated and ready to cook
  • a selection of carbohydrates - either couscous, rice, mash and/or vegetables (grilled peppers, roasted onions, and other restaurant style vegetable ideas were developed)
  • some kits would also contain a fresh sauce or salsa, separately packaged.

The meal kit would be packaged in 'easy grab' transparent boxes, rather like take-away boxes. Each kit would serve one and be priced between £3.79 & £4.99. The range was to be 'idiot proof' for the consumer to prepare, so it had three simple cooking instructions for either conventional oven or microwave (75% of UK households own a microwave).

The protein element would be pan fried. Cooking time from start to finish would be 10 minutes. The consumer could also put some of their preference into the dish, eg. by choosing to cook their steak rare, medium or well done in the case of fillet of beef with wild mushroom sauce.

When the first samples were shown to buyers, the company realised that they may be on to something big. It was suggested that they might launch a whole range of 'meal kits' featuring meat and poultry as well as fish. The marketing department decided to commission some research, because the concept would cost the company a significant amount to develop.

A key part of this research was to show factory samples to consumers to gauge their reactions to the product concept and packaging:

  • did consumers understand the fit between the product concept and packaging?
  • did consumers understand how the product was to be used?
  • to which consumer groups will meal kits have the greatest relevance and appeal ?

Research was undertaken in three areas of England - Staines, Central London & Birmingham. Different households were targeted, egs. pre-family, main-Sainsbury's shoppers and post-family, secondary-Sainsbury's shoppers. The main findings of the research were :

  • the idea of 'meal kits' is very appealing to a wide range of consumers
  • the recipe ideas were also very appealing
  • even though there are similar products on the market, this concept is more stylish
  • the product name (meal kits) carries a negative connotation - it reminds people of 'Blue Peter' and does not do the product justice
  • the price was perceived as good, many consumers expected it to cost more
  • the portion size was seen as being generous
  • family and non­family meals were seen as a key division, ie. this product would not be bought instead of a family meal

Other research already conducted in 1998 was also used, because it related to the consumption of convenience foods:

  • 85% of meals now eaten in the home are convenience meals
  • in the 1980s, consumers were prepared to spend 1 hour per day preparing meals; in the 1990s they are prepared to spend a maximum of 30 minutes This research gave enough positive feedback for the continued development of the range.

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About the manufacture
Sourcing of the raw ingredients for Fresh Creations was important to guarantee a consistent result each time, eg. fillet of lamb has different eating qualities depending on the country of origin and size of animal slaughtered. Similar problems can be found with beef. In one dish, Spanish Piquillo Peppers, which are harvested and then lightly smoked, these were imported to add an authentic flavour to the finished dish. The dishes were all developed in a test kitchen before being transferred to a factory environment. The factory staff were trained to replicate the texture, flavour and appearance of the range accurately and consistently. The recipes were then scaled up for production in large, walk-in ovens and steamers.

Many of the dishes, eg. risotto cakes, were made individually by hand. This is extremely labour intensive, but necessary for the freshly prepared, 'hand-made' image. The type of equipment used in the production of this type of product is less automated or 'high-tech' than might be imagined. This is because the volume of output is much lower than for standard product lines. Also because the recipes could be abandoned or changed at any time. High-tech machinery is not always flexible enough to cope with this level of uncertainty and so is a less appropriate choice, as well as being expensive.

This product range presented a challenge to the manufacturer as all three components of the 'meal kit' had to be treated and processed in completely different ways. The main factor was that all elements must take no longer than 10 minutes to prepare and that the cooking instructions had to include both microwave and conventional cooking guidelines. Some vegetables, egs. green beans and broccoli, were left raw with a little water in the base for microwaving, or with instructions to cook conventionally (ie. steaming or boiling). Vegetables that were pre-cooked were carefully timed so that they would be of the best possible eating quality even after being re-heated.

Some individual recipes presented a challenge, eg. a sea trout used for a recipe dish was not recognised by consumers and they were wary of it. They understood trout to be pink and tender with small, thin fillets. The sea trout being trialled was the size of salmon which was not what consumers expected, so the product was renamed chunky trout. A change in name has helped gained sales and consumer confidence. All products were developed with a 4-5 day shelf life. This was not achieved with the risotto cakes which went soggy during shelf life tests and did not present well after 2-3 days. They were, therefore, withdrawn after an initial trial period.

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About the marketing
Research identified that consumers found the name 'meal kits' a bit "Blue Peter-ish". So, a professional product-naming team were bought in to come up with a name that really said what the product was all about - and so Fresh Creations was born!

Originally 20 recipe ideas were put forward of which 12 ended up in the first product launch.
These were:
Thai Vegetable Curry Cod
Provencale Pork loin with Mustard Sauce Fillets of Beef with Wild Mushroom Sauce Moroccan Style Lamb
Chunky Trout and Mustard Mash
Risotto Cakes Tuna & Mash Salmon with White Wine Sauce Lamb Escalopes with Rosemary Sauce
Chicken Kashmir with Rice and
Naan Chicken Fajitas

The key factors controlling the selection were set by the development team, according to what they thought would and would not sell. They were concerned about the range being considered too 'new wave' (trendy). Sainsbury's has tended to stick to more traditional style products and was concerned that they would be unsuccessful if they left this safety net.

So, for the first products in the range, the team stuck to more traditional style recipes and developed more radical ideas later, when the range was extended.

This was an interesting decision considering that the range was being marketed directly at the young, pre-family and single household market who were most likely to be more adventurous with their choice of food. These are people who have little time to spend preparing food ('time poor') or who simply do not want to spend their spare time in the kitchen.

Packaging design is an integral part of product development. Packaging designers were asked to develop the product pack from an idea the development team brought back from Japan. They had been on a tour of Japan to investigate its food, products and culture. They were impressed with the simplicity and elegance of aluminium lunchboxes (oblong with three tiers or compartments) seen there. The design team were asked to focus on this idea, but to use clear plastic instead of aluminium because the product was to be visible.

The product information was to be presented on labels around the product, not on the bottom of the pack. This was to avoid consumers turning the pack upside down to read the product information, then putting the product back on the shelf with the clear film smeared with the contents. This had to be avoided, since the packaging is used to sell the product, as well as to protect the contents.

Fresh Creations is no longer available at Sainsbury's because it was discontinued, but it is still an interesting example of how a product range is developed.

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About issues and values
All retailers are in competition with one another. In today's fiercely competitive market it is not enough simply to sell the best quality food at the right price. It is also crucial to be innovative, to be first with new ideas and to be a leader. For some time Sainsbury's were market leaders, with Tesco in second place. More recently, Tesco has found its way into the top position, with many others just behind, egs. ASDA and Morrison's who offer quality food at a lower price and good value. The Food Centre, therefore, plays an important role in this aspect of Sainsbury's work and many different strategies have been put in place to support innovation in food product design.

A much wider variety of fresh foods is now available in the UK due to advances in technology and design. Many of these foods are also convenience foods, which means that those who do not want to spend too much time in the kitchen can eat conveniently, but still enjoy fresh foods. But how much innovation and how many new products do consumers need and want? Does the food industry respond to consumer need, or does it encourage consumers to respond to the retailer's need to sell increasingly more products? The food industry is, after all, in the business of being commercially successful and making money.

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Making use of the case study - things to think about and do
Using this case study for the following tasks will help to develop your understanding about:

  • new product development - how a companies innovate
  • industrial practices - product prototyping, trialling and manufacturing
  • the role of market research in new product development
  • values issues - whether companies respond to, or create, consumer needs
  • Examine the consumer need that the Fresh Creations range is based upon. What does this tell you about eating habits in today's society? Is Fresh Creations a product that meets this need? In what other ways could it be met? Put forward alternative proposals.

  • Are there any changes you would make to improve or extend the Fresh Creations range - either the products, the packaging or marketing, or to be targeted at other consumer groups? Trial one or two of your ideas and evaluate their feasibility.

  • There are numerous similar products to Fresh Creations on the market, egs. M&S Cafe Range, Tesco Finest. Carry out a costing exercise to compare the cost of:

    buying a dish from one of these ranges
    eating it in a restaurant
    buying it as a take-away
    making it from scratch yourself.

  • Also calculate the time taken to prepare and cook each of these options. Which represents the best value for money for each of the following circumstances?

    a single business person who works long hours
    a family of six
    a couple who are bored with eating out.

  • Having carried out your market survey, do some 'future-gazing' and predict any other innovative meal trends for 2000 and beyond.

  • How would you suggest adapting (or recipe engineering) the production process of one of the Fresh Creations meals to make it less labour intensive. Produce an annotated flow diagram of the process. What impact would this have on the quality of the product?

  • Fresh Creations is no longer available because it was discontinued - can you suggest any reasons for this?

  • A version of Fresh Creations could be re-launched in the future. This is a way of drawing consumers' attentions to the product and re-awakening their interest in it. If it was your job to re-launch the range, what would you do and why?


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    Further useful resources
    'Nuffield Food Technology 14-16 resources', Longman, 1996, p46-48, p132-140
    'Food Technology in Practice', DATA, 1996, p18-21, p54-57
    'D&T Routes: Food' , RCA, Hodder & Stoughton, 1997, p63-65, p77-81
    'Design & Make it: Food Technology¹, Stanley Thornes, 1997, p62-63, 146-157
    'Food Technology' Unit, British Nutrition Foundation, 1998, MAFF
    'Food Technology', Collins Real World Technology series, Inglis, Plews & Chapman, p86-87, 119-127
    'Examining Food Technology', Anne Barnett, Heinemann, 1996, p15-21
    'HACCP' CD-ROM, Economatics - industrial case studies, including cook-chill foods
    www.readymealsinfo.com
    www.defra.gov.uk-
    for information on National Food Surveys
    www.technology.org.uk
    - case study on chilled Indian foods
    Click here to connect to 'Being a product developer' case study in the F-files

    ©foodforum.org.uk 2000. All rights reserved

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