Consultant - Industrial Feasibility for Tom Brown Reformulation

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The International Rescue Committee (IRC) responds to the world's worst humanitarian crises, helping to restore health, safety, education, economic wellbeing, and power to people devastated by conflict and disaster. Founded in 1933 at the call of Albert Einstein, the IRC is one of the world's largest international humanitarian non-governmental organizations (INGO), at work in more than 40 countries and 29 U.S. cities helping people to survive, reclaim control of their future and strengthen their communities. A force for humanity, IRC employees deliver lasting impact by restoring safety, dignity and hope to millions. If you're a solutions-driven, passionate change-maker, come join us in positively impacting the lives of millions of people world-wide for a better future. Consultancy - Terms of Reference (TOR) Title: Consultant - Industrial Feasibility for Tom Brown Reformulation Total number of Consultants: 1 Country Program: Nigeria Proposed Dates: May - June, 2026 Duration: 2 months Background of the project IRC is exploring whether Tom Brown can be reformulated into a safer, more consistent, treatment-grade product for moderate acute malnutrition (MAM) in Northeast Nigeria. The goal is to define a product that remains locally familiar, affordable, and practical to prepare, while meeting stronger standards for nutrition, safety, quality, and production consistency. This consultancy focuses on the industrial feasibility side of the work, with explicit goals to: Define the industrial feasibility constraints and production pathway for reformulated Tom Brown. Clarify what can realistically be produced through local facilities, larger production partners, or a staged pathway across both. Identify the equipment, process, QA/QC, and facility adaptations required for early testing, pilot production, and potential scale-up. Assess 3-4 candidate reformulations against real-world production constraints. Estimate cost, capacity, bottlenecks, and investment needs for moving from early testing to larger production. Identify QA infrastructure gaps and determine what procurement-grade evidence should be collected during prototype production. Scope of work The consultant will lead the definition of industrial feasibility constraints for reformulated Tom Brown and translate those constraints into practical decisions for formulation, production, and scale-up. 1. Define industrial feasibility constraints and production pathway (Primary Deliverable) a. Define the feasible production pathways for reformulated Tom Brown, including roasting, milling, blending, extrusion, or hybrid approaches. b. Identify the key constraints that should shape formulation and production decisions, including machinery, batch size, throughput, process control, ingredient handling, oil content, aflatoxin risk, rancidity, moisture control, shelf stability, and production consistency. c. Clarify which constraints are absolute red lines, which can be solved through adaptation, and which should be tested during prototype or pilot production. 2. Translate constraints into a usable feasibility framework a. Produce a clear decision framework that helps IRC understand: What can be produced locally now What could be produced with modest adaptation What would require larger investment or a different production partner What is not feasible under current conditions Key trade-offs between cost, manufacturability, stability, quality, and complexity The framework should be practical enough to guide formulation selection, partner engagement, and next-stage pilot planning. 3. Assess local production pathways and facility types a. Map the relevant local production economy, including hammer mills, processors, packaging actors, ingredient suppliers, and larger production partners. b. Assess which facility types could plausibly support early formulation testing, pilot production, or larger-scale production. c. Identify where IRC may be able to contract with existing local facilities, where technical upgrades would be required, and where production may need to ladder up to more capable partners. d. Identify QA infrastructure gaps at each candidate facility against institutional procurement expectations (e.g., UNICEF Supply Division, WFP). 4. Define equipment, process, and QA/QC requirements a. Identify the machinery, process steps, utilities, labor, and facility conditions required to produce reformulated Tom Brown safely and consistently. b. Define minimum QA/QC and food safety requirements for pilot production and scale-up, including examples such as raw material acceptance criteria, aflatoxin controls, moisture thresholds, heavy metal limits, microbiological testing, traceability, batch records, and finished product testing. c. Identify where third-party lab testing, external QA support, or additional technical oversight would be required. 5. Determine what procurement-grade evidence should be collected in prototype production a. Define the raw materia

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