Treloar Product Development

Top Stories

Experimental Design brings much-needed efficiency to product development

Product development teams are always looking for new ways to "work smarter, not harder".  Treloar Product Development uses a well-honed approach which results in shortened development time, reduced development cost and superior products and processes.


Developers know that prototypes can be designed that work "perfectly" on the bench. They develop the formula that meets targets for flavour, texture, nutritional profile, ingredient cost, etc. In the pilot plant, or in production trials, the prototype often behaves differently. In response, the developers change the formula and / or the process. Full scale manufacturing involves more changes and "tweaking" of the formula and process. Finally, the product meets the consumer and, regrettably, problems in product performance may also appear. The developers are thrust into emergency "redevelopment" to fix the product.

The continual appearance of new factors affecting product performance is well known. We are aware of the likelihood of problems at several stages, such as moving the prototype into the pilot plant; scaling up to manufacturing; and during packaging, distribution and consumer use. But today's critical paths for development do not afford time for problem solving and redesign.


This cycle of making changes in response to variation is expensive in money and in time.  As each product change is made, more testing is needed. Changes to the product and process add cost: development costs in staff hours, ingredients and plant trials; and opportunity costs of delayed product introduction.


The traditional approach depends on waiting until the product gets into trouble and then dealing with the problem, making changes as each new variation appears.  The essence of experimental design is to anticipate variation and develop the information needed to "dial in" the required product performance.  With greater understanding of the key factors controlling performance, the developer can efficiently make adjustments and design the product that will more consistently deliver the desired performance under varying conditions. By using these methods, the formula that is most resistant to variation can be developed at the lowest cost. This high quality/low cost combination has been successfully achieved in thousands of development projects in many different industries. When applied to food products and processes, it can yield extraordinary results!

The Treloar Approach

  • Efficient
  • Experienced
  • Cost-effective
  • Confidential