Perfect in the Pilot Plant. Cracking on the Line.
Image is for illustrative purpose only - actual product may vary.
The Problem Statement
A premium choc-coated bar sailed through pilot trials — then cracked, flaked and bled coating at full line speed, while cold-chain abuse tests broke the pack seal in monsoon humidity.
Founders’ Involvement, Experience and Hack
Lived on the factory floor: re-tempered the coating and rebuilt its rheology for line-speed pickup, matched enrobing and hardening-tunnel profiles to the new spec, and co-developed a higher-barrier laminate and seal geometry with the packaging supplier.
Commercial Scale & Impact
Scaled to national and APAC production on schedule — the same lab-to-line rigour later delivered bars at 15 MT scale for Indian Metros first and then Tier-2 cities
Case stories are illustrative retellings of real project experience across these brands