When One Variable Changes Everything

Here’s a real-world example of why even small changes between development and first production matter. During benchtop testing, a new low-sugar ice cream flavor was transferred immediately into a deep freezer after it was developed. Because it was cooled almost instantly, the product remained smooth and showed no noticeable ice crystal formation, performing very similarly to the original full-sugar version. Based on those results, the formula was approved to move forward to first production.

During the first production run, however, the process introduced a key difference. Due to the way the production line was scheduled that day, the ice cream sat for 20 to 30 minutes before entering the large freezing tunnel. That delay proved critical for the low-sugar formulation. Unlike the standard flavor, the new version contained more unbound water. During the extended hold time, that water migrated, allowing ice crystals to form and grow before the product reached the deep-freeze stage. By the time freezing was complete, the ice crystals were large enough to create a noticeably grainy texture.

This example illustrates why teams must carefully evaluate any changes introduced during scale-up, including hold times, line scheduling, and equipment flow. While plant trial data provides valuable insight, every new variable can affect product performance. Identifying and assessing those differences as a cross-functional team helps ensure that first production delivers the intended quality, not unexpected surprises.