2012 R&D Team Winner: Kettle Cuisine

Refrigerated and frozen soups for discerning (but busy) restaurant chefs.

By Diane Toops, News and Trends Editor

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Kettle Cuisine RD TeamRecognizing a niche opportunity in foodservice, Jerry Shafir combined his business school knowledge and passion for soup by founding Chelsea, Mass.-based Kettle Cuisine Inc.. His vision was to provide the same quality, all-natural, made from scratch, refrigerated soups to discerning restaurant chefs as those they made themselves, saving them labor costs and taste and texture inconsistencies – soups they would be proud to serve their customers.

Twenty-six years later, Kettle has some 200 employees, is still privately owned, and the company's product portfolio has grown to more than 60 varieties of soups, chilis, chowders and stews. The company serves more than 5,000 restaurants, cafés, bakeries, cafeterias, delicatessens and supermarkets in the U.S.

When Shafir's daughter Kate was diagnosed with celiac disease nearly 20 years ago, Shafir realized how limited the prepared gluten-free food options were for this growing community of people. In 2006, when the FDA proposed a formal definition for gluten free foods, he launched a line of 10 chef-inspired single-serve bowls of all-natural, gluten-free frozen soups, which are now available in grocery stores nationally.

Kettle Cuisine's mantra is that the quality of what comes out of a soup kettle is highly dependent upon the integrity of the ingredients that go into the kettle. In order to maintain the integrity of its products, the company takes great pride in having cooks and chefs practice artisan cooking techniques in its kitchens. Perhaps that's the reason the company has grown significantly while the overall soup category has declined.

Corporate Executive Chef Joseph Ascoli leads the cross-functional team with an open mind and gathers ideas from as many different sources as possible.

"Our core competence is premium quality, all-natural kettle cooked foods in both refrigerated and frozen formats for foodservice," he says. "We specialize in soups, chowders, chilis and stews but we also make a few sauces and dips, and we recently launched organic steel-cut oatmeal. We have more than 60 varieties of soup available every day under the Kettle Cuisine brand. We also cook a wide range of proprietary products for specific customers with which we co-develop recipes. These products are primarily packaged in bulk 4- and 8-lb. pouches."

All of Kettle's foodservice products are also available in retail. "Beyond selling bulk soup for our customers' hot soup wells, we also sell soups in refrigerated deli cups in sizes between 12 and 32-oz.," explains Ascoli. "All of our retail sales are private label and branded with our customers' own labels."

Reflecting on the reason for the success of Kettle's R&D team, Ascoli admits, "There is no silver bullet. However, our success is largely a result of embracing a true team approach, setting aside egos and carefully listening to the market. While we have a dedicated R&D team of culinary professionals, we view R&D as the responsibility of the entire company, and we include every department in the process. This inclusive approach helps us come up with a wider range of ideas and helps us commercialize new products much more efficiently and effectively.

Joseph Ascoli"Further, we embrace a very open minded approach to R&D. We have a lot of experience in our category based on years of trial and error, but we realize we can still learn and improve, so we routinely and proactively facilitate feedback and we continuously evolve. Finally, we spend a lot of time reading about consumer trends, dining out, speaking to customers about their needs and never rest on past success -- we are always looking for the next great idea."

The core R&D team includes Ascoli, R&D Chef Diego Marigorda, Director of Product Development Steve Sharpe and Sandy Rega, one of Kettle's marketing directors.

"My responsibility is to oversee the entire culinary process from ideation through scaling up recipes in the kitchen," says Ascoli. "Diego is responsible for cooking all of the preliminary test batches and helping me come up with recipes that deliver on the product concepts we are targeting. Steve is responsible for scaling up recipes from tabletop samples to larger batches in the kitchen and monitoring ongoing adherence to specification. And Sandy is responsible for facilitating all of the discussions that lead to new product development concepts.

Throughout the process, the R&D team works with other departments at Kettle. "All departments are involved early and often throughout the process," he says."A few examples of how this works is that purchasing helps us understand the availability of ingredients, marketing helps identify new concepts, sales continuously keeps us informed of customer needs, and the management team provides guidance on the best approach for commercializing each new variety.

"We have a standing R&D meeting every Monday that includes representatives from culinary, sales, marketing, finance, operations, purchasing, customer service and quality assurance to review all of the concepts in development. Our founder and CEO Jerry Shafir also is always present at this meeting.

Ascoli notes the timeline for new products can be as short as two weeks or as long as six months. "Most commonly, a new product takes about four to six weeks. We start with ideation sessions to come up with new concept ideas, then build numerous prototypes that are tested internally," he explains. "Once these concepts are narrowed down we bring in consumer panels for testing, make adjustments and take the product out to a few key customers and channel partners for testing. We then begin the scale up process."

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