Mike Noonan

Every company in the food business talks sustainability. It’s a feel-good concept, often addressed in generalities and a decades-long time frame.

For Mike Noonan, vice president of operations for Bitchin’ Sauce, the time for sustainability is “now.”

“Food waste is a huge problem,” says Noonan, 36. “And much of that waste occurs on the consumer level, with people throwing away products that are out-of-date. That can be addressed through consumer education but can also be controlled through the manufacturing process.”

In 2009, Noonan received his Bachelor of Business Administration degree in Operations Management from the University of Cincinnati. His plan was to work within the supply chain and ultimately manage a large distribution center.

The recession interfered and he ended up working the night shift at a $7-billion cheese manufacturer—Schreiber Foods in Logan, Utah.

Noonan was then recruited to join EVOL Foods in Boulder, Colorado, a frozen food manufacturer, followed by a stint at Boulder Brands. He also spent nearly four years at a pet food company, followed by time at Astronaut Foods, a manufacturer of freeze-dried products. “I have worked in almost all aspects of food manufacturing—frozen, refrigerated, freeze-dried, even pet food,” he says.

A chance encounter at a cousin’s wedding introduced Noonan to Bitchin’ Sauce. “I had driven eight hours and was starved. I ate Bitchin’ Sauce all night.” A few months later, the owners approached him to join as vice president of operations, “a dream opportunity.”

Extended Shelf Life

Bitchin’ Sauce is an almond-based refrigerated dip that can be used as a spread, dip, or cooking ingredient. It was founded by husband-and-wife duo Starr & L.A. Edwards and comes in 16 flavors, including Bombay, Chili, and Salted Caramel. The problem was its 30-day shelf life which limited its ability to be sold beyond the local market.

The challenge was solved by High Pressure Processing. The dip receives 87,000 pounds of pressure for 180 seconds, eliminating salmonella, listeria, E. coli and other potential contaminants. HPP also extends the shelf life to four to six months, allowing Bitchin’ Sauce to expand distribution.

“HPP requires very expensive machinery. We have found partners in Los Angeles and San Diego to work with us,” says Noonan. “The process is used primarily for cold-pressed juices and the companies need to run the machines 24/7 to maximize their investment.”

Noonan and the 35 operations employees also keep a close watch on waste at the plant. Loss is less than 3 percent. “Ingredients are our highest cost factor so we work hard to control that. We buy top-quality almonds but they do not need to look perfect for processing. We also keep a close eye on sales and projections, so we are not making more product than we can sell,” he says.

Extra finished product is donated to the San Diego Food Bank or Feeding San Diego. Unfinished product is composted.

Noonan also serves as a board member for Naturally San Diego; he is the sole operations person on the board. He brings a new perspective to the group that is mostly composed of company founders and sales and marketing executives. “Operations is often overlooked in the industry. It is an important part of the business and of profitability,” he says.