The moment you pick one up, you feel its satisfying weight. The wrapper is thin yet pleasantly chewy, and as you bite into the hearty chunks of pork and zucchini, your mouth instantly floods with savory juices – you just cannot help but smile.
“This is not just an ordinary mandu.”
That was my honest reaction to bibigo Juicy Pork Stuffed Mandu, released this March. But who are the masterminds behind this culinary masterpiece? As expected – but no less impressive – achieving this perfect balance of texture, flavor, and juiciness in this mandu took dozens of tests and countless failures over a two full years of development period, nearly double the time typically needed for similar products. To uncover the story behind this one perfect bite, we sat down with Kang, Bo-kyeong and So, Wan-seob, the CJ CheilJedang researchers who brought this breakthrough product to life.
Got a Problem with Mandu?
Korea’s frozen mandu market has long reached maturity. With products like bibigo Original Mandu holding the top position since 2013, amid numerous established competitors, developing something truly innovative meant identifying the unmet needs of consumers – a significant challenge in and of itself.
“Consumers were already quite satisfied with existing products. Rather than searching for a new need, we decided to take a step back and ask what people really expect from mandu.”
The 2023 consumer research revealed two essential insights: consumers want mandu with “mouth-filling juiciness” and “authentic texture of real ingredients.” These findings led researchers to define the Golden Standard – mandu with a translucent wrapper showcasing the substantial filling, chunky and hearty ingredients, and abundant meat juice in every bite.
However, achieving this standard presented serious technical challenges.
All That Trouble for Juiciness? From Filling to Wrapper
Delivering the “texture true to the ingredients” required larger pieces in the filling, which immediately presented a major obstacle: forming. Traditional toothed forming machines tend to grind or mash the ingredients during the filling process, making it impossible to preserve the desired texture.
“We needed entirely new equipment. We had to redesign the process from the ground up to handle large ingredient pieces without damaging them, all while scaling up the production process.”
But it was not simply a matter of acquiring new machines. Introducing new equipment meant overhauling the entire production line – an enormous undertaking.
“It took more than just the R&D team’s commitment. We had to persuade related departments and executives. Saying ‘we need new equipment’ was not enough. We had to prove how this could unlock a whole new range of product possibilities.”
After extensive deliberation and discussion, the team introduced a compartmented forming machine that gently pushes, rather than injects, the filling, preserving the ingredient texture. With the filling issue resolved, they turned to the next challenge: the wrapper.
“Larger filling creates more pressure and tension on the wrapper. But if the wrapper is too thick, consumers cannot feel the chunky texture of ingredients. We needed something thin yet resilient – a precise balance.”
To deliver a truly satisfying “mouthful” mandu, the team gradually increased the mandu’s weight while maintaining a precise 3 cm height – ideal for a single bite. Every detail was meticulously calculated to meet exacting conditions.
“The wrapper needed to be stretchy to maintain the height, but higher gluten content makes the dough cloudy. We adjusted the formulation dozens of times to achieve the perfect balance – transparent yet elastic.”
Large chunks of filling also presented another challenge: moisture. The team worked to minimize moisture transfer from the filling to the wrapper while still meeting the ambitious target of 25% juice content in the mandu.
“We have been working to boost juiciness for years. This time, we did not just aim to increase it – we pushed the limits of what is possible within a frozen mandu format.”
In pre-launch sensory evaluations*, the bibigo Juicy Pork Stuffed Mandu scored an impressive 4.3 out of 5 – the highest rating ever among CJ’s long line of mandu products.
*Testers score food based on taste, texture, aroma, and overall appeal.
Experience Built in China and Japan
The project, which began in March 2023, was far from easy. Behind every challenge solved in crafting this one perfect mandu was the global experience and expertise of the two lead researchers. So, Wan-seob brought eight years of expertise from the R&D team in China, while Kang, Bo-kyeong had developed a wide range of products, including Japanese-style dumplings, Vietnamese spring rolls, and even plant-based mandu.
“China offers an incredible variety of dim sum with fillings that truly maintain their texture. After years of working in that environment, I naturally gravitated toward creating mandu where you could distinctly experience each ingredient.” – So, Wan-seob
“Japanese dumplings tend to have softer textures with abundant juice. This naturally led me to focus on details like that satisfying burst of juiciness the moment you take a bite.” – Kang, Bo-kyeong
Is the bibigo Juicy Pork Stuffed Mandu an end to the two-year research? Absolutely not. Throughout the lengthy development process, the team gathered valuable insights and experimental data. With additional innovative products already in development for global markets, there is much more to anticipate.
“You know how mandu sometimes burst while boiling? The Juicy Pork Stuffed Mandu stays perfectly intact, even after 10 minutes in the pot. My personal favorite way to enjoy them is as mandu soup.”
Kang shares her go-to recipe for enjoying the Juicy Pork Stuffed Mandu – one she wished could have been included on the packaging. Simply boil the bibigo Beef Bone Broth with an extra 100 ml of water, add the Juicy Pork Stuffed Mandu, and simmer for 10 minutes. The result? A rich, comforting bowl of Sagol Mandu-guk that only gets better the longer it cooks. Why not give this hearty soup a try for dinner tonight?
