report on co-packing for brooklyn food manufacturers
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STEPHEN T. LEVIN
NEW YORK CITY
COUNCIL MEMBER
33RD DISTRICT,
BROOKLYN
OCTOBER 28, 2013
CO-PACKINGfOR BROOKLYN
fOOD mANufACTuReRS
RePORT ON
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CONTRIBuTORS
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ADDITIONAL CONTRIBuTORS: Harry Rosenblum, Eric Demby, Chris Woehrle, Kari Morris,
Miquela Craytor, Lydia Downing, Alissa Weiss, Hunter Goldman, Katie Codey, Monica Foskett,
Andrew Steininger, Carlo Scissura and Cailtin Dourmashkin
RAmI meTALPRjEC MAAGER
KImBeRLY GOLEAD PLC ER
CARINA GARCIAPLC ER
BeNeDICT JOSONER
mATT OJALAEDR
AShLeY ThOmPSONEDR
ANTONIO m. RODRIGuezREPR DESG & LA
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fORewARD
exeCuTIve SummARY
INTRODuCTION
SuRveY BACKGROuND AND meThODOLOGY
ReSPONDeNT PROfILe
SuRveY fINDINGS
I. CuRReNT LImITATIONS
II. eCONOmIC GROwTh
III. BROOKLYN mATTeRS
Iv. A SOLuTION
fOOD CATeGORY PROfILeS
CONDImeNTS, SAuCeS, AND SYRuPS
BAKeD GOODS
meATS AND SeAfOOD
ReCOmmeNDATIONS
CONCLuSION
SeLeCT SuRveY ReSPONDeNTS
SuRveY
TABLe Of CONTeNTS
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For those of us interested in good food, there is no better place to live than ew ork City.
ncreasingly -- thanks to food manufacturers from the City expanding their businesses -- more
and more amazing food products that you could once only get here can now be enoyed across
the country. Brooklyn has been responsible for much of this output and has, over the past few
years, been the home to an explosion of local, artisanal food manufacturers who are making a
name for themselves not only in ew ork, but nationally and even globally.
et, despite the boom of the Brooklyn food manufacturing industry, consistently hear from
small business owners leading this food movement that they are having difculty expanding
their businesses. here is a demand for more of their products and a desire for their businesses
to grow, but there have not always been good answers as to how to make that happen. Brooklyn
food manufacturers are outgrowing their current facilities, have limited access to kitchen
space and appropriate equipment, or are simply unable to nd a manufacturing space that
suits their needs.
n order to help meet the needs of Brooklyn food manufacturers -- business leaders who play a
vital role in our local economy -- my ofce has worked with organizations like the Brooklyn
Chamber of Commerce, Pratt Center for Community Development, and the East Williamsburg
Valley ndustrial Development Corporation, along with government partners like Brooklyn
Borough President Marty Markowitz, Assemblyman joe Lentol, the ofce of C Council SpeakerChristine Quinn, and the Economic Development Corporation to explore new ideas that can help
build on the growth of the industry thus far. his report explores one such idea: a Brooklyn based
co-packing facility that can be utilized by food manufacturers from across the borough.
he Brooklyn food manufacturing industry is strong. Whether it is through the introduction of
a co-packing facility or the implementation of other innovative ideas, we can make it even
stronger. am proud to work alongside the food manufacturers of Brooklyn and am excited to
see how the industry can thrive as we continue to work together.
Stpn T. Lin
ew ork City Council Member
33rd District, Brooklyn
forord ro Concil mbr Stpn T. Lin
410 Atlantic An Brooklyn, NY 11217 [email protected] (718) 875-5200
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ExEcutivE SummaryAs one o the astest-growing industries in Brooklyn, ood manuacturing has contributed greatly to the economic
growth o the borough in recent years. The strength o the Brooklyn ood manuacturing industry is refected in its gross
sales and reach outside the borough, as well as the jobs it has generated in a time o high unemployment. Despite this
strength, many Brooklyn ood businesses have reported a number o challenges in growing their business.
In May 2013, Council Member Stephen Levin sent a survey to Brooklyn ood manuacturers to assess their production
needs and level o interest in a local co-packing (contract packing) facility, which manuactures and packages oods
or other products or their clients, that could potentially address production issues. The businesses were asked about
their level o interest in co-packing; business size and labor prole; product, equipment, and ingredient specications;
type o acilities currently utilized or production; shel stability and storage requirements, and interest in pick and pack
services. The results were tabulated in July 2013 with the intent o presenting them to stakeholders or eedback nec-
essary to determine the viability o Brooklyn co-packing.
Based on our results, we ound that current limitations in acilities, projected growth, and a desire to be in Brooklyn are all
contributing actors in a general dissatisaction among ood entrepreneurs with their current situation. We ound that ood
manuacturers do in act want a co-packing acility allowing them to increase business fexibility and cut overhead costs:
1. 68% o respondents eel their current manuacturing acilities limit their production capacity.
2. 31% o respondents expect their gross sales to all between $500,000 and $1 million or more in 2013.
62% expect their gross sales to all within this range in 2015.
3. 60% o respondents said it was o signicance or their production acility to be in Brooklyn.
4. 45% o respondents are very interested in a Brooklyn-based co-packing acility while an additional
16% would sign up now i the option were available.
In addition to our ndings, this report oers three visions or a co-packing acility based on the ood products that had
the largest representation in the survey: condiments, sauces, and syrups; baked goods, and meats and seaood. It also
oers ve paths or the implementation o such a acility:
1. The NYC Economic Development Corporation (EDC) commits to releasing an Request or
Expression o Interest (RFEI) to be ollowed by a Request or Proposals (RFP) or a Brooklyn based
co-packing acility.
2. EDC or the NYC Small Business Services (SBS) provides a subsidy to Brooklyn based
Victoria Co-Packing in order to allow them to accommodate smaller quantity runs or local ood
manuacturers.
3. Local not or prot applies or city capital unding to go towards the build out and purchase equipmentor a space to be used as a co-packing acility.
4. Private party applies or IDA unding in order to help create a co-packing acility.
5. Food manuacturing cooperative creates a member based co-packing acility.
It is our hope that this report will be inormative and highlight the importance o co-packing to Brooklyn and NYCs
ood industry and greater economy.
7
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1 Brooklyn Labor Market Review, Brooklyn Chamber o Commerce, Winter 2012, http://www.ibrooklyn.com/CWT/EXTERNAL/WCPAGES/WCMEDIA/DOCUMENTS/BLMR%20WINTER%202012%20FINAL.PDF 2 Ibid.
3 Copacker Wikipedia: The Free Encyclopedia. Wikimedia Foundation, Inc., 13 July. 2013. 4 Paul Young. Q & A: Co-Packing As A Competitive Advantage, Manuacturing.net, August 23, 2011, http://www.manuacturing.net/articles/2011/08/q-%26-a-co-packing-as-a-competitive-advantage.
introductionFood manuacturing has become one o the astest-growing industries in Brooklyn. Once thought o as a niche market,
Brooklyn artisanal ood manuacturing businesses have integrated into the mainstream. Brooklyn has become a brand,
and provides a cachet or consumers who wish to buy locally produced and distributed ood products.
The strength o the Brooklyn ood manuacturing industry is evident in its gross sales and its reach outside o the borough.Nearly a quarter o the output o Brooklyn ood and beverage manuacturers is sold outside o the borough, with $326
million in domestic sales occurring outside o Brooklyn and $134 million o that output exported outside o the U.S. 1
Growth in the industry also means jobs or the residents o Brooklyn. In 2011, there were 372 ood manuacturers employing
5,650 workers and an additional 377 Brooklyn ood manuacturing businesses who do not report any employees.2 The
ood manuacturing business in Brooklyn has only continued to grow since 2011.
But despite the strength of the Brooklyn food manufacturing industry, these companies still face a number of challenges
in growing their business; chief among them is a limited amount of space to manufacture their product.
Small ood manuacturers continual growth is refected in their long term plans to develop and expand their acilities.
In a separate survey conducted by Council Member Stephen Levin in May 2012, 52% o small ood manuacturers that
responded indicated that their current acility is not sucient to accommodate their business or the next two years and60% o respondents are searching or larger or more appropriate production acilities.
Respondents to the May 2012 survey also indicated that Brooklyn matters. The importance o having a Brooklyn-branded
product was seen as important by 90% o respondents looking or space in Brooklyn. At the same time however, 77% o
respondents are having diculty nding an aordable space in Brooklyn to work rom. One respondent said, We had a
7,000 sq oot warehouse that we outgrew and moved production outside the city due to cost.
While there is a desire to produce in Brooklyn, available spaces are either too costly or have little to no inrastructure.
Commercial kitchens require costly capital expenditures and must meet the standards o the US Department o Agri-
culture (USDA). Most o the available industrial spaces were historically used as warehouses and storage and need a ull
rehabilitation. With increased interest in Brooklyn neighborhoods driving up market rents, landlords rarely need to oer
to make capital improvements in order to draw tenants. These actors have already lured ood businesses outside o
the borough and, let unchecked, could potentially drive more companies to more aordable cities. When asked about
aspects o their business that would be able to grow better outside NYC, one respondent replied, Everything is cheaper
outside NYC so naturally the bottom line is not quite so deep i one moves production outside o the city.
With a desire to stay in Brooklyn and a need for more space, a solution is needed for Brooklyn food manufacturers to al-
low them to stay in Brooklyn and continue to grow their thriving businesses.
One possible solution that has been articulated recently is the establishment o a co-packing acility in Brooklyn that would
be able to meet many o the production needs o the burgeoning Brooklyn ood manuacturing industry. A co-packer, or
contract-packager, manuacturers and packages ood or other products or clients under contract with the hiring company to
manuacture as though the products were made directly by the hiring company.3 Co-packing allows ood manuacturers to
increase business fexibility and cut overhead costs as the acility already has the expertise, resources and sta in place.4
To better understand the desire or such a acility in Brooklyn and what it might look like, a survey was sent to Brooklyn
ood manuacturers by Council Member Stephen Levin in May 2013. This report examines the ndings rom this survey
and outlines recommendations based on the ndings.
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SurvEy Background and mEthodologyThrough discussions with many new Brooklyn ood businesses, it became clear that the lack o aordable production
space and the high capital costs involved in outtting a space are the most critical inhibitors to strong business growth
or Brooklyn-based manuacturers. In May 2013, Council Member Stephen Levin sent a survey to Brooklyn ood manu-
acturers to assess the production needs o Brooklyn ood manuacturers and level o interest in a local co-packing
acility that could potentially address production issues.
The survey was sent out in May 2013 to over a hundred ood manuacturers over the internet, o which 70+ responded
between May 1, 2013 and July 1, 2013. Participants were identied by telephone, e-mail and in person, by Council
Member Stephen Levin and his sta, at Smorgasburg Flea booths and other locations which are representative o
the burgeoning Brooklyn ood scene. The East Williamsburg Valley Industrial Development Corporation (EWVIDCO),
Brooklyn Chamber o Commerce, Brooklyn Kitchen, The Brooklyn Flea, and the oce o New York City Council Speaker
Christine Quinn were also instrumental in identiying survey participants.
The survey contained 53 questions about the nature o the respondents business and interest in a co-packing acility in
Brooklyn. (See Appendix for the complete survey.) It asked respondents to rank their level o interest in Brooklyn co-pack-
ing and how important it is or their production acility to be in Brooklyn. It also asked respondents how many employees
they have, the percentage o cost o goods allocated to labor and production, and whether they are interested in addi-
tional services such as pick-and-pack or wholesale and online orders. These and other questions are critical to our under-standing o whether a Brooklyn co-packing acility would be easible and desirable -- and i it is, what it should look like.
rESpondEnt profilEThe 70+ businesses that participated in the survey are predominantly emerging companies that employ 10 people
or ewer. While the majority o respondents (66%) were companies that either produced in Brooklyn or were based
in Brooklyn but produced their project outside o Brooklyn, the survey also attracted a number o respondents rom
outside the borough. There were nine (9) respondents who either produced in or were based in Manhattan as well as
15 respondents who manuacture their product in Long Island City rom incubators such as The Entrepreneur Space
and Organic Food Incubator. O these 15 respondents, six (6) have oces in Brooklyn while three (3) have oces in
Manhattan. O the businesses that were based in Brooklyn, 38% have production acilities outside the borough.
O the businesses that participated in this study, the ood
categories with the largest representation are Meats/Sea-
ood (22%), Baked Goods (26%), and Condiments, Sauces,
and Syrups (38%). This inormation is important because
co-packing operators and ood entrepreneurs have advised
against a one size ts all type o acility, instead advocating
or a acility that specializes in one category o ood prod-
ucts. A specialized acility would reduce the cost o equip-
ment and increase trust among manuacturers who value
eciency and expertise.
A handul o respondents outside the norm o the oodmanuacturing business opened our eyes to additional pos-
sibilities as we looked urther into co-packing. These include
S.W. Basics, a cosmetics company that uses vegetables ex-
clusively in their products; Bartleby and Sage, which special-
izes in catering and event planning; and Jersey Lynne Farms,
a wholesale ood distributor in Canarsie looking to establish
a private label. These unexpected responses suggest that
other businesses besides those that we are targeting will be
interested in using a co-packing acility.
9
What podcts do yo podc?
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5 Stephen Kleege, A Tight Lid On Food Artisanals, Crains New York, March 10, 2013, http://www.crainsnewyork.com/arti-cle/20130310/HOSPITALITY_TOURISM/303109990#article_tab. 6 Kleege, A Tight Lid On Food Artisanals.
10
SurvEy findingSIn conducting the survey, we sought to determine whether or not a co-packing acility would be a viable solution to many
o the challenges local ood manuacturers ace today. We rst sought to identiy and understand the nature o these
obstacles by asking about the production needs and challenges o Brooklyn-brand ood businesses. We ound that current
limitations in acilities, projected growth, and a desire to be in Brooklyn are all contributing actors in a general dissatisac-
tion among ood entrepreneurs with their current situation.
I. Curren LIIIn
52% o rspondnts lt tir crrnt acility cold not scintly accoodat tir bsinss or t
nt to yars, and 60% said ty r actily sarcing or largr or or appropriat acilitis.
Liitd accss to sard kitcn spac ans tat all prodction as to b don at spcic ors and
ood prodcrs sotis do not gt t sits tat ar bst or tir scdl.
Or ridg liits t aont o ingrdints tat can a rady to go. Or storag spac liits t
inntory can a on and. Or orkbnc liits o otn can do a prodction rn.
Kari Morris, Morris Kitchen
Chie among our ndings was that Brooklyn ood manuacturers have had diculty nding needed space in Brooklyn
to conduct their business. Our study ound that they have had diculty nding suitable real estate to expand, and are
having trouble expanding within the spaces they are currently located as their businesses continue to grow.
Food businesses in Brooklyn ace many diculties nding suitable real estate. In the May 2012 survey, which ocused
more broadly on the Brooklyn ood manuacturing industry, 68% o respondents reported that they were looking or
space in Brooklyn; however, 52% indicated that nding aordable space was an issue. Citywide, the vacancy rate or
industrial space is about 4%, and rents range rom about $11 to $20 per square oot. 5 Most available kitchen and retail
spaces have little to no inrastructure and
require costly capital expenditures that can
run up to $200,000 or more or stoves,
rerigerators and other required equip-
ment.6 Meat businesses in particular also
need acilities that are USDA-compliant,
which necessitates even greater capital
investment.
Accommodating growth is another
contributing actor to the search or new
space. In 2012, 52% o respondents elt
their current acility could not suciently
accommodate their business or the next
two years, and 60% said they were ac-
tively searching or larger or more appro-
priate acilities. As the suitability o a oodbusinesss space is strongly correlated
with the size and requency o its pro-
duction runs, it is not surprising that we
ound in 2013 that 68% o respondents
eel their current manuacturing acilities
limit their production capacity.
Do yo fl yo ct mafactigviomt limits gowth?
YeS NO
Notyt
,butm
ightint
hfutu
rNot
sur
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7Is Manuacturing Back in Brooklyn? Center or an Urban Future, March 2013 http://nycuture.org/data/ino/is-manuacturing-back-in-brooklyn 8 Brooklyn Labor Market Review, Brooklyn Chamber o Commerce, Winter 2012
Many ood entrepreneurs nd themselves articially inhibiting growth because o space and time limitations. When asked
what type o acilities they use or manuacturing, 34% o respondents report commercial kitchens and 11% report incu-
bators -- in other words, shared spaces. Limited access to shared kitchen space means that all production has to be done
at specic hours and ood producers sometimes do not get the shits that are best or their schedule. One respondent
says, Kitchen closes at 5 so my vegetable deliveries sometimes cannot get there on time and have to be delivered at my
apartment. Right now, I can handle that because I am small, but in a couple o months that wont be possible anymore.
Sometimes the appropriate equipment is unavailable in shared kitchens, which means ood producers cannot make asmuch o their product even i demand is high. One respondent notes, We do not have a stable temperature room or
ermentation. We do not have a comprehensive ltration system, bottling machine, or label machine. Another says, We
do not have sucient ovens or racks to bake more than we currently do. Even i equipment is available, access is oten
limited because o space and time constraints. With many ood manuacturers unable to invest in the equipment they
need, they have no choice but to keep runs articially small.
Lack o control over production space also limits the amount o inventory that can be bought and product that can be stored. In
situations where ingredients need to be rozen or rerigerated, lack o control could mean spoiled supplies and wasted unds.
II. eCnIC GrW
31% o Brooklyn ood bsinsss pct tir gross sals to all btn $500,000 and $1 illion or orin 2013, and 62% pct tir gross sals to all itin tis rang in 2015. I ts bsinsss rain in
Brooklyn, tir total gross arnings ill dobl, ro $21 illion in 2013 to $42 illion in 2015.
wil only 10% o rspondnts pct to prodc 100,000 nits or or in 2013, tis nbr is pctd
to tripl by 2015. Today, 20% o sry rspondnts ar prodcing daily; tis nbr is pctd to or
tan dobl by 2015, it 47% o rspondnts projcting tat ty ill b prodcing daily itin to yars.
Our study also ound that the Brooklyn ood manuacturing industry is growing. Once thought o as a niche market,
Brooklyn artisanal ood businesses have integrated into more mainstream outlets. Whole Foods recently unveiled a
partnership with Smorgasburg to eature a new vendor every month on the second foor o their Bowery location. Cen-
tral Parks Summerstage and Prospect Parks Bandshell use small, Brooklyn-based ood manuacturers or their events
throughout the summer. Companies such as Morris Kitchen, which began as an artisanal syrups vendor at Smorgasburg,
have expanded and are now receiving orders rom major retailers such as Whole Foods and Williams-Sonoma.
While Brooklyns manuacturing sector has suered signicant job losses in recent years, its ood manuacturing sub-
sector has managed to retain and even add jobs to the economy. From 2000-2010 Brooklyn lost nearly 24,000 manu-
acturing jobs7 and yet the ood manuacturing sector has consistently employed around 6,000 people throughout that
time period. In 2011 there were 372 Brooklyn ood manuacturers employing 5,650 workers plus an additional 377 ood
manuacturing businesses that did not report employees, about one third more than a decade ago.8 And these businesses
are growing- when asked about their employment projections in 2012, respondents expected to add a total o 62 new ull
time jobs and 80 new part time jobs by May 2013, resulting in a 53% growth in ull time jobs and 63% growth in part
time jobs. The average respondent employs 3 people ull time.
The strength o the Brooklyn ood manuacturing industry is evident in its gross sales and reach outside o the borough.Nearly a quarter o the output o Brooklyn ood and beverage manuacturers is sold outside o the borough, with $326
million in domestic sales occurring outside o Brooklyn and $134 million exported outside o the U.S.7 These gures are
only expected to increase over the next two years and beyond. 31% o Brooklyn ood businesses expect their gross sales to
all between $500,000 and $1 million or more in 2013, and 62% expect their gross sales to all within this range in 2015. I
these businesses remain in Brooklyn, their total gross earnings will double, rom $21 million in 2013 to $42 million in 2015.
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What do yo pojct yogoss sals to b ovth xt 3 yas?
What is th pojctd fqcy of yo podct s ov th xt 3 yas?
NumBeR Of ReSPONDeNTS
PeRCeNTAGe Of ReSPONDeNTS
NumBeR Of ReSPONDeNTS
What is th pojctd siz of yo podct s ov th xt 3 yas?
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The continued growth o Brooklyn ood businesses is also
refected in their projections or production capacity. While
only 10% o respondents expect to produce 100,000 units
or more in 2013, this number is expected to triple by 2015.
Today, 20% o survey respondents are producing daily;
this number is expected to more than double by 2015, with
47% o respondents projecting that they will be producing
daily within two years.
Sustained economic growth requires production acilities and
tools that meet businesss varied needs. When asked about
the type o acilities they currently use, 34% o respondents
report shared commercial kitchens; 27% use co-packers (all
outside o NYC), 21% use privately operated kitchens, and
11% use incubators. The ve most widely used equipment
items are sheet trays (49%), mixers (43%), bottling equipment (38%), a brand o ood processor called the Robot Coupe (35%),
and speed racks (30%). Packaging options range rom glass jars (24%) to plastic containers (22%) to sealed pouches (20%).
Storage is important or the growth o ood businesses as it ensures the reshness and saety o ingredients and nished products.
In addition to the 38% o respondents whose ingredients require room temperature storage, 40% rerigerate their ingredients and
22% reeze them. The breakdown or storing nished products is similar: 44% o respondents need their products to be stored atroom temperature, 34% need their products to be rerigerated, and 21% manuacture products that require reezing.
Food entrepreneurs are very interested in reeing up time and
capital to increase their growth potential. 80% are interested in
a wholesale pick and pack ulllment service while 82% are
interested in a pick and pack service or online orders. I these
services were made available, ood entrepreneurs would have
more time to devote to business development while putting dis-
tribution in the hands o a acility that can bring them to market.
A respondent says, As we increase production, we will need to
ocus less on sel-distribution and more on sales and having our
product managed/distributed by third party networks.
III. BrkLn er
w old lo to b clos to r or prodcts ar
anactrd. w startd aking or prodct in
Brooklyn and ar basd r.
Jessica Quon & Sabrina Valle, The Jam Stand
Our study ound that ood producers want their acilities to be in
Brooklyn. When asked how important it is or their production acility
to be in Brooklyn, 60% o respondents said it was o signicance.
The reasons or this are myriad. By being closer to their product,
ood entrepreneurs can exercise more control over quality and pro-
vide direction to their labor orce. Quality control and assurance is
a top priority or these businesses, many o whom believe that their
business growth is most attributable to the high quality o their
products, and thereore believe that being in closer geographic
proximity to their production acility enables them to have ar more
control over the quality o their product. One respondent says, Dis-
tance is very dicult. [Employees] do not understand what were
trying to do, and they work at a dierent pace than we do.
13
What id of facility do yo ctlys to ma yo podcts?
ow impotat is it foyo podctio facilityto b i Booly?
1 Ver Irn 5 n Irn LL
ow impotat is Booly to yo bad imag?
NOT AT ALL exTRemeLY
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Moreover, ood producers take pride in their identity
as Brooklyn-based businesses. When asked how
important Brooklyn is to their brand image, approxi-
mately 70% said very important or extremely
important. Meanwhile, businesses that do not pro-
duce in Brooklyn -- whether they originated there or
are eyeing the cache o the Brooklyn brand -- aspire
to claim this identity or themselves. Food producersalso value the community o like-minded individuals
that comprise the entrepreneurial spirit o Brooklyn.
No matter how we look at the data, it is apparent that
Brooklyn matters to ood manuacturing businesses.
IV. LuIn
wn askd o intrstd ty r in a Brooklyn-basd co-packing acility, 45% o rspondnts said
ty r ry intrstd, il an additional 16% old sign p no i t option r aailabl.
The challenges that Brooklyn ood
entrepreneurs ace call or a solution
that will better serve their needs
and promote the continual growth
o the ood manuacturing industry.
Our ndings show that these
entrepreneurs want a co-packing
acility as that solution.
When asked how interested they
were in a Brooklyn-based co-packing
acility, 45% o respondents said they
were very interested, while an addi-
tional 16% would sign up now i the
option were available. Moreover, at a
workshop sponsored by the Brooklyn
Chamber o Commerce on February 26, 2013, many entrepreneurs argued that city tax breaks and other incentives
were needed to attract co-packing and that having such a acility in Brooklyn would be wonderul.9
Further analysis o the survey ound that a Brooklyn based co-packing acility would attract the 62% o businesses that
currently produce in the borough. O these businesses, 63% said that they were either very interested or answered
sign me up now or copacking. Moreover, 83% eel their current acilities are limiting growth, leaving them in dan-
ger o moving production elsewhere i they cannot nd suitable space in Brooklyn. Establishing a co-packing acility
in Brooklyn that can accommodate their growth would enable them to continue producing in the borough; otherwise,
these businesses will continue to look elsewhere or acilities that do.
A co-packing acility in Brooklyn would also attract the 40% o businesses that do not produce in Brooklyn. O these
businesses, 66% would either sign up now or be very interested in a co-packing acility. Furthermore, hal o the
respondents who believe it is o signicance or their production acility to be in Brooklyn do not currently produce in the
borough, and approximately 80% o this group is interested in a Brooklyn-based co-packer. Many o these businesses
began producing in Brooklyn but space limitations orced many to leave. Increasing space and production capacity would
allow them to return to Brooklyn.
14
o what dg do yoattibt th gowth of yocompay to th qality ofyo podct?
9 Kleege, A TIght Lid On Food Artisanals.
Wold yo b itstd i a Booly-basd co-pacig facility?
Not sure [15](need to know more)
Not interested [4]
Interested [7]
Very Interested [33] Sign me up [12]
Like the idea ingeneral but wont workfor my business [2]
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Two companies that currently use out o state co-packers, Brewla Inc. and The Brooklyn Salsa Company, stated that they
would sign up now i a acility was available in Brooklyn. While these companies are still considered small, employing
ewer than 10 employees, they have enjoyed steady growth over the past ew years. Brooklyn Salsa is sold in 800+ stores
in New York City and has over 1,200 accounts nationwide, including the New York City stores. They are also sold in Lon-
don, Tokyo and now Thailand. This refects the enormous growth potential that co-packing has to oer, and why a acility
in Brooklyn would be a welcome addition to the boroughs ood chain.
It is worth mentioning that co-packing already exists in Brooklyn in the orm o Victoria Fine Foods. However, Victoriahas not, as o yet, been willing to accommodate the smaller production runs o many emerging ood businesses.
Smaller runs require more requent production changeover than do larger runs and that turnover accounts or a
decrease in protability or larger co-packers. Emerging Brooklyn ood manuacturers have tried to meet the minimum
number o units required o Victoria clientele, but their quantities remain too low. Unless this changes, Brooklyn runs
the risk o losing out on millions o dollars in economic growth that continues development o the ood manuacturing
industry would bring.
food catEgory profilESIt should be clear that in advocating or a co-packing acility we are not advocating or one that can meet the needs o
every type o ood producer and product. Food manuacturers have repeatedly stated that the quality o their product
is paramount and that quality suers when a acility is making baked goods one minute, sauces the next, and someother type o ood right ater that. Aside rom the higher costs associated with equipping a kitchen or manuacturing a
variety o ood products, the main concern is that in trying to serve every need, product quality will suer.
Specialization is the key in co-packing and thereore we believe that a potential Brooklyn co-packer should specialize
in one particular ood category. Given that the majority o the companies we have surveyed have been making either
condiments/sauces/syrups, baked goods, or meats/sh, it is recommended that one o these three categories be
prioritized or co-packing. Further analysis would have to be done by a prospective co-packer to determine which
category would be the most viable.
CnDIen, uCe, nD ru
At 38% o respondents, producers o condiments, sauces, and syrups had by
ar had the largest representation in the survey; it would thereore tap into a
very large market. One respondent says, I eel to help the most people pos-
sible you guys should ocus on bottling - jams, pickles, sauces and etc. Thats
your biggest market - those people will always be popping up.
A co-packing acility or these products would eature the ollowing equipment
needs: bottling equipment (74%), mixers (50%), and a type o ood processor
called a Robot Coupe (50%). Since 55% o condiments, sauces, and syrups
producers already use co-packing outside o New York City, it stands to
reason that they would be interested in transerring operations to a co-packing
acility closer to home.
Meanwhile, the industry will only continue to grow. The average condiments,
sauces, and syrups producer expects to increase their run size over the next
two years. Whereas only 20% o producers expect to manuacture more than 50,000 units in 2013, 51% expect to all
into this range in 2015. Moreover, the requency with which producers manuacture is also expected to increase. Only
21% o businesses are producing on a daily schedule in 2013, but 57% expect to be producing daily in 2015.
A acility that serves the condiments, sauces, and syrups producers has the greatest potential to contribute to Brooklyns
economy. These ood manuacturers already generate $6.4 million in gross sales; by 2015, this is expected to rise to $9.6
million, an increase o 50%.
15
What facilitis do yo s?
ANSweR %
OTheR (plas spciy) 0%
INCuBATOR 8%
PRIvATeLY OPeRATeDKITCheN
19%
ShAReDCOmmeRCIALKITCheN
42%
CO-PACKING fACILITY 46%
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C0-PACKING For Brooklyn Food Manufacturers16
BkeD GD
Baked goods producers ace restrictions on equipment that limit their production run sizes. The three most important
equipment needs or baked goods producers are sheet trays (89%), speed racks (61%), and mixers (61%), all o which
come in varying sizes and quantities and need to be upgraded to accommodate growth. One respondent says, Our small
kitchen-aid stand mixer limits batch size, and commercial licensing is not
available at home. Another says, We do not have access to anything larger
than 60 quart mixers. With this in mind, it is no wonder that 77% o baked
goods producers believe their current acilities limit business development.
A co-packing acility that serves baked goods producers would acilitate
growth in production capacity. With easier access to suitable equipment,
more producers will be able to manuacture on a daily basis. When surveyed
about the expected requency o their production, 33% o respondents said
they would be producing daily in 2013, while 57% expect to be producing
daily in 2015. This, compounded with the 17% increase in respondents who
expect to be producing more than 100,000 units over the next two years,
will surely acilitate the rapid expansion o these businesses.
What is yo pojctd siz ov th xt 3 yas?
What is yo pojctd fqcy ov th xt 3 yas?
Do yo bliv yo ctmafactig viomt
limits gowth?
ANSweR %
YeS 77%
NO 15%
NOT YeT BuT mIGhT INThe fuTuRe
0%
NOT SuRe 8%
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Based on our respondent projections, baked goods would bring in $7 million annually by 2015, a 23% increase over
the current output o $5.7 million. Although this growth is not as large as that o condiments, sauces, and syrups
producers, it is still signicant enough to warrant consideration.
e nD eD
A acility that serves meat and seaood producers would be the only co-packing acility in New York State or meat. As
47% o meat and seaood producers are already using co-packing, it stands to reason that they would be very interested
in utilizing a local acility. Moreover, because o the niche this acility would ll, many businesses in upstate New York or
New Jersey would also be interested in utilizing it, bringing additional growth to Brooklyn.
Because the majority o meat and seaood products are not shel stable (67%), it is important that a co-packing
acility has ample space or reezing and especially rerigerating. Moreover, many meat businesses have expressed
interest in a USDA acility. According to one respondent, I I could operate in a USDA acility, I could increase my
sales 10 old immediately.
17
What is th
pojctdfqcy ofyo podct ov thxt 3 yas?
What is th pojctdsiz of yo podct ov th xt 3 yas?
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Although there are a smaller number o meat manu-
acturers than those o the previous two ood catego-
ries, the industry still has the potential or enormous
growth Whereas no respondents reported run sizes
o 100,000 units or more in 2013, 20% expect their
run sizes to increase to this range by 2015. Likewise,
whereas 25% o meat and seaood manuacturers
are producing daily in 2013, 63% who are expect toproduce on a daily schedule in 2015.
A co-packing acility that serves meat and seaood
producers would ll a niche and bring in the exiles o
an industry that generates $4.7 million in gross sales
annually, a gure that is expected to increase by 28%
to $6 million in 2015.
18
Is yo podct shlf stabl?
If ot shlf stabl, what typ of stoag dos it qi?
What is thpojctdfqcy ofyo podct ov thxt 3 yas?
What is thpojctd sizof yo podct ov thxt 3 yas?
ANSweR %
YeS 61%
NO 39%
ANSweR %
fROzeN 40%
RefRIGeRATeD 60%
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rEcommEndationSFood manuacturing is an integral part o NYCs economy and the increase o new ood manuacturing businesses,
particularly in Brooklyn, has had a positive impact on local employment and economic growth. What is also clear is that
many o these new ood manuacturers either lack adequate production acilities right now or will run out o space soon-
or simply be orced to keep production levels articially low due to space constraints. In order to grow, many o these
businesses have had to manuacture their products outside o New York and this exodus will continue i steps are nottaken to address these constraints.
Co-packing has become an increasingly appealing option or Brooklyn ood manuacturers looking to grow, and stay, in the
borough. Given their desire to manuacture in Brooklyn and all that entails- local jobs, better quality control, more centralized
operations- it is recommended that the City should work to help create the conditions that would allow a co-packing acility
to exist in Brooklyn in the near uture. Based on our ndings we recommend that this acility produce only one type o ood
product to optimize quality and eciency. Outlined below are ve ways that we believe that this can be accomplished.
1. The NYC Economic Development Corporation (EDC) commits to releasing an Request for Expression
of Interest (RFEI) to be followed by a Request for Proposals (RFP).
2. EDC or the NYC Small Business Services (SBS) provides a subsidy to Victoria Co-Packing in order
to allow them to accommodate smaller quantity runs for local food manufacturers.
3. Local not for prot applies for city capital funding to go towards the build out and purchase equipment
for a space to be used as a co-packing facility.
4. Private party applies for IDA funding in order to help create a co-packing facility.
5. Food manufacturing cooperative creates a member based co-packing facility.
OPTION #1 - eCONOmIC DeveLOPmeNT CORPORATION (eDC) COmmITS TO ReLeASING A RequeST fORexPReSSION Of INTeReST (RfeI) TO Be fOLLOweD BY A RequeST fOR PROPOSALS (RfP)
As ood manuacturing represents a critical subsector o the NYC economy, we believe that EDC has a material interest
in the continued health and success o these businesses. EDC is not only in a unique position to urther this policy goal
but has in act been very supportive o the ood manuacturing industry over the past ew years. In addition to hosting the
NYC Food Manuacturers Expo and initiating the NYC Food Manuacturers Growth Fund, among other eorts, EDC has
been supportive o eorts t o urther explore co-packing in Brooklyn.
Given this support and their overall expertise in economic development initiatives, we recommend that EDC put out a
Request or Expression o Interest (RFEI) that will help determine the level o interest in the creation o a Brooklyn based
co-packing acility. Based on the responses to the RFEI, EDC could then either contract directly with one o the respon-
dents or release a Request or Proposals (RFP) that is guided and shaped by the responses to the RFEI.
OPTION #2 - eDC OR The NYC SmALL BuSINeSS SeRvICeS (SBS) PROvIDeS A SuBSIDY TO vICTORIAfINe fOODS IN ORDeR TO ALLOw Them TO ACCOmmODATe SmALLeR quANTITY RuNS fOR LOCAL
fOOD mANufACTuReRS
Victoria Fine Foods is a sauce manuacturer located on E. 100th Street in Brooklyn that, in addition to producing its own
private label sauces, oers co-packing services to outside companies. Unortunately, the minimum quantities that Victoria
requires have been out o the reach o most o the newer Brooklyn ood manuacturers. In order or Victoria to meet
these companies needs, it would be necessary to provide a subsidy to oset the additional costs o the more requent
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C0-PACKING For Brooklyn Food Manufacturers20
turnovers that smaller quantities require. As the largest group o survey respondents were businesses that made sauces,
syrups, jam, and jellies, utilizing existing acilities, at least in the short term, would be an ecient way to expand produc-
tion. In order to determine the appropriate level o subsidy, discussions would need to take place between EDC and/or
SBS and Victoria Fine Foods. As companies grow, they would be able to increase their quantities, thereby decreasing the
amount o subsidy needed. A subsidy to Victoria could also serve as a short-term bridge solution until a permanent acil-
ity that meets the needs o smaller manuacturers can be constructed.
OPTION #3 - LOCAL NOT-fOR-PROfIT OR DeveLOPmeNT AGeNCY eNTITY APPLIeS fOR CITY CAPITAL fuNDINGfOR The BuILD OuT Of A fACILITY AND/OR TO PuRChASe equIPmeNT fOR A CO-PACKING fACILITY
Brooklyn is home to many local development agencies that work to encourage business growth both borough-wide and,
more crucially, in the communities where they are located. A co-packing acility that serves local small businesses would
create local, blue collar jobs and in so doing will help revitalize communities, particularly those where unemployment is high.
A local not or or prot or development agency could apply or city capital unding in order to help nance equipment
purchases and space buildout. These unds would signicantly lower an operators initial capital investment which will
then enable them to work with local, growing companies, who produce smaller and less requent production runs.
OPTION #4 - A fOR-PROfIT eNTITY APPLIeS fOR INDuSTRIAL DeveLOPmeNT AGeNCY (IDA) fINANCINGASSISTANCe IN ORDeR TO heLP BuILD OuT A CO-PACKING fACILITY
The NYC IDA oers various industrial incentive programs that encourage manuacturing by oering various tax exemp-
tions or tax exempt bond nancing on capital upgrades that are deemed necessary to help industrial businesses grow in
New York City. In this scenario, a private party would seek unding rom the IDA in order to help oset the costs o build-
ing out a property that they own to be used as a co-packing acility.
One situation in which this might occur is i the private party is already a ood manuacturer who is looking to expand the
acility that they already have in order to accommodate a co-packing acility or otherwise need help in purchasing the
equipment that would allow or the type o production that a particular co-packing acility would require. The private party
could then either manage the acility themselves or bring in an outside operator to manage the operations.
OPTION #5 - fOOD mANufACTuRING COOPeRATIve CReATeS A memBeR-BASeD CO-PACKING fACILITY
This scenario was suggested by a number o the ood manuacturing businesses that participated in the survey. A coop-
erative co-packing acility would be run and managed by a ew select businesses that would nd a space and purchase
the necessary equipment needed to operate a co-packing acility. The group would begin small but include enough mem-
bers to help spread the capital costs while ensuring that the members were committed and were producing enough runs
to justiy the costs involved in tting out and managing a acility o this kind. Once eciently managed, the membership
would increase, thereby lowering the costs or all while also adding additional services.
concluSionIt is our hope that this report not only quanties the signicant impact that emerging ood manuacturers are
having on Brooklyns economy, but also that it spurs additional investment by public and private stakeholders.As we move towards a new mayoral administration in January 2014, we believe that it is crucial to lay out a
ramework or creating a Brooklyn-based co-packing acility.
We believe that now is the time or action. The longer it takes or a co-packing acility to launch, the more
Brooklyns talented ood entrepreneurs will look to other cities and states to manuacture the products that
were inspired by New York City. This is a critical opportunity that the city cannot aord to miss and we hope
that this report can play a role in helping these small businesses to grow and succeed in Brooklyn, where they
want to be and where they belong.
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C0-PACKING For Brooklyn Food Manufacturers22
SElEct SurvEy rESpondEntS
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C0-PACKING For Brooklyn Food Manufacturers 0025
COuNCIL memBeR STePheN LevIN
* Rird
Plas proid yor na *
his is a required question
wat is t na o yor bsinss? *
Pon Nbr *
wat is yor bsinsss bsit? *
wat is yor bsinss ail addrss? *
Location o r yo prodc yor prodct (Address and Zip Code) *
wr ar yor ocs locatd (if different from previous answer)?
council mEmBEr StEphEn lEvin'S
co-packing SurvEy for Brooklyn
food manufacturErS
Der rIenD,
After hearing from many of the new Brooklyn food businesses that have started up in the past few years, it
has become clear that the lack of affordable production space and the high capital costs involved in outtting
a space are the most critical inhibitors to strong business growth and, in fact, of a Brooklyn food businesses
ability to remain and succeed in Brooklyn. ne possible solution that has been articulated recently is the
establishment of a co-packing facility (a company that manufactures and packages foods or other products for
their clients), located in Brooklyn, that would be able to meet many of the production needs of the burgeoningBrooklyn food manufacturing industry.
What this survey hopes to assess is what the production needs of Brooklyn food manufacturers are and
whether or not a co-packing facility would be a feasible solution that would help meet those needs. Addition-
ally, if co-packing is determined to be a worthwhile option for Brooklyn food manufacturers then what kind
of co-packing facility would make the most sense and what types of businesses would it serve? What kind
of equipment would be needed? Would it specialize in baked goods or perhaps sauces? How much storage
space would be necessary? How many runs would a typical business make in a year and in what quantities?
hese and other questions are critical to our understanding of whether or not a Brooklyn co-packing facility
would be feasible and desirable and if it is, what it would look like.
hank you for taking the time to ll out this survey.
f you have any questions please feel free to reach out to my legislative director, Rai mtal, at (212)788-7348
or by email at [email protected]. As always, can be reached by email at [email protected].
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C0-PACKING For Brooklyn Food Manufacturers26
ho iportant is it or yor prodction acility to b locatd in Brooklyn? *
Very important 1 2 3 4 5 ot at all important
Select a value from a range of 1 to 5.
wat kind o acility do yo crrntly s to ak yor prodcts? *
Privately operated kitchen
Shared commercial kitchen
Co-packing facility
ncubator
ther (please specify)
wat prodct(s) do yo prodc? Cck all tat apply. *
Baked goods
Beer, wine or spirits
Beverages (other)
Condiments, sauces and syrups
Ethnic foods
jams/jellies
Meats/Seafood
Picked produce
Sweets
ther
wat ajor ingrdints do yo s? Cck all tat apply. *
Fresh Fruits
Fresh Vegetables
Meat
Dry ngredients
Liquid ngredients
ther
wat kind o containr/packaging dos yor prodct co in
(glass jar, cardboard bo, sald poc, plastic, clar saran-typ rap, tc.)?
Cardboard box
Clear saran-type wrap
Glass ar
Sealed pouch
Plastic
ther (please specify)
wat is t typ o closr?
Cork
Crown Cap Heat sealed or vacuum sealed
Plasticol cap (for hot ll)
Plastic
Sticher
ther (please specify)
Is an additional tapr idnt rap applid?
es
o
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C0-PACKING For Brooklyn Food Manufacturers 0027
ho any labls ar on ac nit?
1
2
3+
Ar t cass labld?
es
o
Is it sl stabl? *
es
o
I so, or o long? *
I not sl stabl, at catgory is it?
Frozen
Refrigerated
Do yo apply a "Bst by" or "Sll by" dat it a stickr or a dat stap? es
o
wat typ o storag do yor ingrdints rir? Cck all tat apply. *
Frozen
Refrigerated
Room emperature
wat typ o storag dos t nisd prodct(s) rir? *
Frozen
Refrigerated
Room emperature
ho any pallts o spac do yo nd or ingrdints or an arag prodction rn?
(1-3) (4-7) (8-12) (13-20)
Frozen
Refrigerated
Dry
wat ipnt do yo s/rir or ac prodct? Cck all tat apply. * Blast freezer Bottling equipment
Bowl chopper Brewing/fermentation equipment
Casing stuffer Colloid mill
Commercial smoker Conveyor oven
Cryogenic freezer Dehydrator
Fermentation chamber Filter concentrator
Filtration equipment Freeze dryer
Fryer Grinder
Mixer Pasta machine
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Plate pasteurizer Piston ller
Reverse osmosis equipment Robo Coup
Sheet trays Speed racks (how many?)
Slicer Spray dryer
Stovetop win srew extruder
Vaccum chamber Vita prep
ther (please specify)
Do yo s hPP (hig Prssr Pastriation)?
es
o
Plas dscrib yor typical rn si today:
(Size of nits (weight or volume), nits per case, Cases or units per run, Gallons of product per run)
ho any Stock Kp units (SKu) do yo a?
wat is t projctd rncy o yor prodct rns in 2013
wat is t projctd rncy o yor prodct rns in 2014
wat is t projctd rncy o yor prodct rns in 2015
wat is t projctd si o yor prodct rns in 2013 (nits, cass, gallons)?
wat is t projctd si o yor prodct rns in 2014 (nits, cass, gallons)?
wat is t projctd si o yor prodct rns in 2015 (nits, cass, gallons)?
ho any 'prson ors' dos it crrntly tak to prodc on rn o yor prodct?
Do yo bli tat yor crrnt anactring nironnt liits yor rn si/rncy?
I so, y? I not, y not?
Plas stiat t nbr o pallts o storag yo old nd or an arag prodction rn.
Do yo a any spcial rirnts? (i.e. gluten free, nut free, allergen free, kosher, halal, etc)
wat agncy/agncis rglat t prodct(s) yo prodc?
State Department of Agriculture and Markets
Food and Drug Administration (FDA)
S Department of Agriculture (SDA)
Department of Health and Mental Hygiene (DHMH)
Alcohol and obacco ax and rade Bureau (B)
Ar tr any spcial actors/isss inold in yor prodction procss? I ys, plas dscrib.
es
o
Do yo a a bsinss plan?
es
o
wat do yo projct yor gross sals to b in 2013?
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C0-PACKING For Brooklyn Food Manufacturers 0029
wat do yo projct yor gross sals to b in 2014?
wat do yo projct yor gross sals to b in 2015?
wold yo b abl to t a ini o 3,000 nits pr rn?
es
o
ho any ll ti and part ti ploys do yo crrntly a?
wat prcntag o yor cost o goods sold (COGS) gos to labor?
20%
30%
40%
50%+
wat prcntag o yor cost o goods sold (COGS) gos to prodction?
20%
30%
40% 50%
Do yo nd a haard analysis and critical control points (hACCP) plan?
es
o
wold yo b intrstd in prodcing yor prodct at a Brooklyn-basd co-packr? *
Sign me up now
Very interested
nterested
ot sure (need to know more)
Like the idea in general but won't work for my business
ot interested
wold yo b intrstd in a pick and pack sric or olsal?
es
o
wold yo b intrstd in a pack and pack sric or onlin ordrs?
es
o
Plas add any additional conts, concrns, or stions tat yo igt a concrning a Brooklyn
basd co-packing acility.
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