There is a big gap between a product that works on the bench and one that runs reliably in production. Pilot runs are how you cross it. They are small production batches that show you, before you commit to full volume, where your formula and your process disagree.
What a pilot run is for
A pilot run is not a celebration that the product is done. It is a test. The goal is to learn how your formula behaves on real equipment, at a scale closer to production, with the people and process that will make it. Some things that worked in small batches will need adjustment, and that is the point.
What to watch
- Mixing and grinding. Does the mix come together the same way in a larger batch?
- Stuffing or forming. Do sticks fill evenly? Do jerky strips form or slice consistently?
- Smoking and drying. Does product dry evenly across racks and positions?
- Texture and flavor. Does the finished product match your target?
- Yield. How much finished product do you get from your raw material?
- Packaging. Does the product fit and seal properly in its package?
Write everything down
The most valuable thing a pilot run produces is information. Record what you did, what changed, what held, and what you would adjust. Those notes become the basis of your production spec, so the next run, and every run after it, can be made the same way.
Expect to adjust
Most products need at least some changes between pilot and production. That might be a tweak to the formula, a change in process timing, or a different approach to loading racks. It is much cheaper to find these issues in a pilot run than in a full production lot.
Scaling up
Scaling is not just making more. Larger batches can mix differently, equipment can behave differently when it is full, and small inconsistencies become big ones. Good scale-up means understanding which steps are sensitive and controlling them carefully, so the product does not drift as volume grows.
Food safety and validation
Moving to production also means working to confirm your process does what it needs to do, consistently. What that involves depends on your product, your process, and your facility, and it is handled case by case. Build it into your pilot and scale-up plan rather than treating it as a separate step. If you have questions about your situation, email us.
The production spec
By the end of pilot and scale-up work, you should have a clear spec: the formula, the process steps, the checks that confirm the product is right, and the packaging. That spec is what you hand to your team or your co-man, and it is what helps you make the next lot match this one.
Signs you are ready for production
- Pilot runs produce consistent product from batch to batch.
- Your formula and process are written down clearly enough for someone else to follow.
- Packaging runs and seals reliably.
- You understand which steps are sensitive and how they are controlled.
- Your food safety and shelf-life questions have been worked through for your specific product.
If several of these are still open, another pilot run is usually cheaper than a problem in a full production lot.
How 6R helps
Zach runs pilot runs, sets up lines on site, and advises remotely. Whether you are in your own facility or working with a co-man, having someone experienced at the pilot stage can help you learn more from each run and aim for fewer surprises on the way to production. 6R serves North America, the US, Canada, and Mexico, and Zach travels.
If you are getting ready for a pilot run, or your scale-up is not going the way you planned, tell us where you are.
Talk it through with Zach
Email a few lines about your product and what’s in the way. Zach reads it himself, replies, and then you talk on the phone.