A stage-gate process was used to develop a high energy protein supplement that is versatile, economical, nutritional, palatable and shelf-stable. This food item was designed for non-refrigerated tropical areas so that the product could be distributed to hospitals, to sustain disaster relief zones, or be mobilized as short-term aid in food scarcity or unstable food security situations. Nutrition and cost were the two criteria found to be the most important in a survey of hospital patients, medical personnel, and other participants in the general population. A formulation was developed containing a variety of ingredients that were nutritionally desirable, cost effective, flexible, and easily modified to fit local conditions for protracted relief and recovery situations. A production system was developed that: a) reduced the potential microbial load by using a thin diameter product that could be rapidly heated to a temperature that would destroy all detectable microorganisms; b) dehydrated the material to an equilibrium moisture content that would prevent bacterial growth; c) analyzed the vacuum packaged product under simulated storage conditions; and d) established a generic plant production design, HACCP compliance program and label design. Microbial evaluation of processed/stored product indicated no organisms above the typical analytical detection levels. High-resolution electron microscopic evaluation indicated no evidence of remaining muscle structure. Quantity of raw material influenced variations in rheological properties of the emulsion. Extrapolations based on feed consumption during bio-assay evaluation indicated the product increased growth rates consistently in experimental subjects than the three other popular diets currently being used. Chemical evaluation of amino acids, fatty acids, minerals, vitamins, oxidation, energy, water activity and pH, favorably compared with the currently utilized corn meal diet. Cost evaluation of raw ingredients was achieved by benchmark health risk assessment which was economically acceptable. Sensory evaluations by research subjects rated the product superior to the corn meal control. Conjoint analysis by quantitative market research, regulatory issues, global strategy inputs and rapid response emergency interventions found the product showed promise in humanitarian commitments.