Scaling an artisan product demands precise control over formulation and process parameters. For Hot Chip, this journey involved technical support in food and packaging engineering, carried out in collaboration with Teagasc specialists in bakery science, processing and packaging development. Their expertise enabled Hot Chip to translate handcrafted recipes into validated, industrial‑scale processes while preserving the brands premium sensory quality and preparing the product for global distribution.
Challenge: Overcoming the Scaling Hurdle
Hot Chip, an Irish food start-up specialising in premium cookie dough made with real Irish butter, entered the market at a time when consumers were increasingly seeking convenient, indulgent home-baking experiences. While early customer feedback validated the product concept, scaling from small-batch production to a retail-ready offering presented several technical and commercial hurdles.
To grow the business Hot Chip worked with The NPCFC team on achieving consistent product quality as production scaled ensuring that larger manufacturing runs matched the original standard and ensuring a robust shelf life without sacrificing flavour, texture or overall sensory appeal. Innovative design and processing helped ensure the product remains resilient throughout distribution, merchandising and consumer handling, maintaining its signature indulgence from factory to consumption.
These challenges presented not only technical barriers but also strategic opportunities and solving them would allow Hot Chip to transition from a promising start-up to a scalable, export-ready Irish food brand.
Solution: Scientific Support & Refinement
After completing the Food Works Programme, Hot Chip continued its collaboration with Teagasc to access deeper scientific, technical, and innovation support. Through a structured development process, Teagasc provided expertise across bakery science, formulation optimisation, food safety, and packaging engineering.
Key areas of support included:
- Optimising product formulation for consistent quality.
- Validation and extension of shelf life to meet retail and export requirements.
- Development of packaging formats that balanced functionality and consumer appeal.
Impact: National Launch & Export Readiness
The partnership between Hot Chip and Teagasc delivered a technically robust, commercially scalable product that resonated strongly with both retailers and consumers.
- Successful national retail launch Hot Chip secured listings with major Irish retailers including Dunnes Stores and Tesco, achieving strong early sales and repeat purchase rates.
- Improved operational confidence – Validated shelf life, optimised formulation, and reliable packaging, the company gained the technical foundation needed to scale production and meet growing demand.
- Strengthened brand positioning – The refined product quality and premium packaging reinforced Hot Chip’s identity as a high-end Irish bakery brand, differentiating it in a competitive category.
- Export readiness – Proven retail traction and a stable, scalable product, Hot Chip is now well positioned to enter international markets, targeting premium retail channels and speciality food sectors.
