R&D RADIO: Colleen Cottrell, Independent Consultant at C Cottrell Consulting

The Startup CPG Podcast · 27 Apr 2026 · 24m · Episode 297

What this episode covers

Colleen Cottrell, an independent food science consultant and former employee of RXBAR, explains how ingredient functionality—specifically how heat, pressure, and shear alter protein behavior—impacts the scalability of CPG products. She details the functional differences between liquid and dried egg whites, shares DIY assays for testing foaming and gelling, and discusses the technical challenges of expanding RXBAR into new categories like oats. The conversation also covers current market trends, including protein and fiber maxing, the importance of PDCAAS scores for protein quality, and the shift toward whole, real ingredients.

Other shows on the same ground, closest first.

  • How I Built This · 47m

    Live Episode! RXBAR: Peter Rahal

    Peter Rahal, founder of RXBAR, and his co-founder Jared Smith explain how they launched a protein bar company in 2013 by targeting the CrossFit community with a minimal-ingredient product made in a Cuisinart. They bootstrapped the business with $10,000, selling directly to gyms and online, and eventually scaled to $36 million in sales before Kellogg's acquired RXBAR for $600 million in 2017. Rahal details the critical decision to dump $300,000–$400,000 worth of inventory due to shelf-life stability issues with an early co-packer, a move that preserved brand integrity despite causing a temporary stockout.

  • People of Packaging · 1h 09m

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    Ree Dolnick, founder of JECA Energy Bars, explains how she transitioned from cancer research to building a self-manufacturing CPG brand after co-packers rejected her clean-label recipe and demanded unfeasible run sizes. She details the company's pivot to in-house production developed with RIT engineers, which allowed JECA to control quality and offer short turns that retailers like Whole Foods and Wegmans prefer. Dolnick also discusses the iterative packaging journey, moving from plain film to digital printing and finally to ePac pouches, while emphasizing the importance of customer discovery at UB Cultivator to identify the true buyer profile.

  • How I Built This · 42m

    Advice Line with Peter Rahal of RXBAR

    RXBAR co-founder Peter Rahal joins Guy Raz to answer questions from three early-stage founders: Kristi Stewart of Inner Wellth Supplements, Eric of Squat Wedgies, and April Waktel of Cheeky Cocktails. Rahal shares insights on scaling via high-intent digital ads, balancing Amazon volume with direct-to-consumer margins, and refining product messaging for trade versus consumer audiences. He also reflects on his new venture, David Protein, and the importance of overcoming founder pride to accept criticism.

  • How I Built This · 48m

    Advice Line with Pete Maldonado and Rashid Ali of Chomps

    Pete Maldonado and Rashid Ali, co-founders of the meat stick brand Chomps, discuss the 'proteinification' of the food industry and how a recent, costly product recall reinforced their commitment to consumer safety. They advise Yari Dariz of Yadi Artisanal Empanadas on scaling strategies, suggesting a commissary model and delivery to manage seasonality, and counsel Zachary of Noble Pies on proving velocity and incrementality to break into big-box retailers like Whole Foods. Finally, they guide Josh Shrinko of Achigan on when to transition his smallmouth bass lifestyle brand from part-time to full-time, emphasizing focus on high-margin product lines like lures.

  • People of Packaging · 1h 10m

    350 - Beyond the Dieline - Dr Juan from PNuff Crunch joins Tom Seymour

    Dr. Juan Salinas, founder of Pnuff Crunch, discusses his transition from food science roles at Nabisco, Cadbury, Kraft, and Nestle to launching his own functional snack brand. He details the operational challenges of scaling production, specifically the costly mistake of over-purchasing long-run packaging film rolls and the strategic pivot to digital printing and smart plate design to manage inventory. Salinas also recounts his viral Shark Tank appearance, where Mark Cuban’s intervention saved the pitch, leading to Cuban’s investment, and explains how Pnuff Crunch’s high-protein, high-fiber formulation targets modern dietary trends including GLP-1 companion foods.

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