REFORMULATION & PRODUCT TROUBLESHOOTING

Reformulation & Product Troubleshooting

A good concept deserves a formula that works.

When taste, texture, stability or manufacturing gets in the way, we help you understand the problem and develop a practical path forward.

Existing formulasNew prototypesCommercial products
01 / FIND YOUR STARTING POINT

Good ingredients.
A product that still needs work.

Select the issue closest to yours. These are starting points for discussion; the right investigation depends on your formula, process and results.

FOCUS AREA / 01

Taste & aftertaste

A formula can make sense on paper and still be difficult to take every day. We help identify what is driving the sensory problem and what can realistically change.

What we review

  • Ingredient forms, extract specifications and dose contributions
  • Sweetener balance, acidity, flavour direction and aftertaste
  • Serving size, dilution instructions and intended use
  • Constraints around sugars, allergens and ingredient declarations

Possible next steps

  • Prioritize the ingredients contributing most to the problem
  • Compare ingredient forms or suppliers before adding more flavour
  • Plan structured bench trials with clear comparison criteria
Helpful to bring

Current formula, ingredient specifications, preparation instructions and a description of when the unpleasant taste appears.

THE DEVELOPMENT BRIEF

Keep what matters.
Reconsider what doesn’t.

Before changing a formula, we establish the priorities. What needs to improve? Which ingredients, doses or claims are essential? What are the limits on cost, serving size and manufacturing?

Intended benefitDaily experiencePractical doseManufacturing fitTarget costMarket requirements

A useful recommendation makes the trade-offs visible, so you can decide what to develop next.

02 / ACROSS PRODUCT FORMATS

The format changes.
The questions get more specific.

Our review starts with how the product is made, stored and used—not just the ingredients on the label.

01

Powders & drink mixes

Flavour, wetting, dispersion, sediment, foam, serving size and moisture-related handling. Includes hydration, protein, fibre and multi-ingredient blends.

02

Capsules & tablets

Dose loading, fill weight, powder flow, excipient selection and manufacturing feasibility. Disintegration and other performance testing can be scoped with suitable laboratories.

03

Gummies, chews & lozenges

Active loading, texture, flavour, ingredient distribution and packaging considerations, with specialist process development through the appropriate manufacturer.

04

Liquids, drops & shots

Taste, separation, settling, pH, dose delivery and packaging compatibility. Microbiological and preservative-related questions are referred for suitable testing.

05

Bars, bites & functional foods

Protein and fibre loading, texture, flavour, serving practicality and changes during storage. Product classification and labelling are reviewed for the intended market.

06

Specialist delivery formats

Feasibility review for oral films, pouches, gels, jelly sticks and other formats. We help define the technical questions and identify when specialist development is needed.

03 / A STRUCTURED PROCESS

From a recurring issue
to a defined plan.

Some projects need a focused review. Others need several development rounds. We agree the scope before starting and identify where external work is required.

01

Understand the problem

We start with the formula, product history, target customer and what is going wrong. We also establish what must stay: key ingredients, claims, format, cost or launch timing.

EXPECTED OUTPUT

A clear brief and an initial list of information gaps.

02

Review the likely causes

We compare the formulation, ingredient specifications, process, packaging and available results. Possible causes are separated from conclusions that still need testing.

EXPECTED OUTPUT

A prioritized technical review and investigation plan.

03

Develop practical options

We identify changes worth evaluating and explain the trade-offs. Depending on scope, this can include revised formulas, ingredient alternatives and a structured bench-trial plan.

EXPECTED OUTPUT

Defined reformulation options and trial criteria.

04

Evaluate and refine

Trials and laboratory work are performed by the agreed development or testing partners. We help review the findings and determine what to retain, change or investigate next.

EXPECTED OUTPUT

A documented comparison of results and recommendations.

05

Prepare the handoff

The agreed changes are organized for your manufacturer and regulatory workflow. Further stability, performance or market-access work is identified before commercial decisions are made.

EXPECTED OUTPUT

An updated technical package and next-step checklist.

04 / CLEAR DELIVERABLES

Work you can take
into the next conversation.

Deliverables are selected for your project. A focused formula review and a complete reformulation program involve different levels of work.

Technical formula review

An assessment of the current composition, key constraints and questions that need investigation.

Reformulation options

Proposed changes with a clear explanation of dose, taste, format, sourcing and cost trade-offs.

Ingredient comparison

Relevant differences between ingredient grades, specifications and supplier documentation.

Trial & testing brief

Variables to compare, observations to record and external tests to consider.

Manufacturer handoff

A revised formula or development brief, agreed instructions and unresolved technical questions.

Results review

Interpretation of trial or laboratory findings against the agreed development targets.

Where external partners fit

Laboratory testing, manufacturing trials, specialist process development and regulatory submissions are included only when expressly agreed. We can help coordinate these activities; external fees and responsibilities are established in the project scope.

05 / MAKE THE FIRST DISCUSSION USEFUL

Bring the problem.
We’ll help frame the next step.

You don’t need every document to start. Use this checklist to organize what you have, then copy or download a short brief for your enquiry.

What do you already have?

0 of 7 information items selected. This is a preparation checklist, not a readiness score.

Your project at a glance

Keep this high level; there is no need to enter your confidential formula here. This tool does not submit or save your brief. Copy or download it before leaving the page.

06 / COMMON QUESTIONS

Before we get started.

A few practical details about scope, confidentiality, testing and working with your existing partners.

Can you work with a formula we already have?

Yes. Projects can start with an existing commercial formula, a prototype or a manufacturer’s proposal. We first confirm what information is available and whether the issue can be assessed from documents or needs samples and testing.

Can you improve taste without removing the important ingredients?

That is often the objective, but the options depend on the ingredients, their amounts and the format. We review the main sensory contributors and compare changes in ingredient form, flavour balance, serving approach or processing. Where a compromise is needed, we explain it before recommending a change.

Can you make a large capsule serving or scoop smaller?

We can assess the options. These may include reviewing ingredient priorities, suitable concentrations, powder density or an alternative format. We do not assume that a smaller dose will deliver the same benefit or support the same claims.

Do you perform the laboratory tests yourselves?

Our service focuses on technical review, planning, coordination and interpretation. Analytical, microbiological and stability testing is arranged with appropriate third-party laboratories when included in the agreed project scope. Laboratory fees are quoted separately unless expressly included.

Can you establish or extend the shelf life?

We can help plan the evidence needed and review appropriate stability data. A shelf-life recommendation depends on the specific formulation, packaging, storage conditions and results. A formula review alone does not establish an expiry date, and an accelerated study is not an automatic substitute for longer-term evidence.

Will you work directly with our manufacturer?

Yes, where agreed. We can help clarify technical questions, compare ingredient options, review development results and prepare a clear handoff. Manufacturing decisions and process validation remain with the responsible manufacturer and qualified personnel.

Can you help find another manufacturer or ingredient supplier?

Sourcing support can be included or scoped separately. The brief should establish technical requirements, documentation needs, expected volumes and suitable production capabilities before comparing suppliers or manufacturers.

Does a reformulation require a new regulatory submission?

It depends on the market, product classification and the change. Ingredient amounts, forms, claims, directions or other particulars may require regulatory action. We flag this for product-specific review rather than assuming the existing authorization covers the revised product.

Can you help with novel ingredients or difficult delivery formats?

We can start with a feasibility assessment covering the dose, evidence, ingredient status, format limitations and manufacturing options. Specialist formulation, process development or testing may need a suitable external partner.

How long does a project take, and what does it cost?

Timing and fees depend on the quality of the starting information, the number of formulas and the need for trials or external testing. After an initial discussion, we define the scope, deliverables, dependencies and fees. Laboratory turnaround and manufacturer trial schedules are considered separately.

Can we discuss a confidential formula?

Use the initial enquiry to describe the problem at a high level. Confidentiality arrangements and an appropriate way to share technical documents can be agreed before detailed formulation information is exchanged.

What if we do not know what is causing the problem?

That is a reasonable starting point. Share what you can observe, when it happens and whether it affects every batch. We can help define the questions and the information needed for a structured investigation.

LET’S LOOK AT WHAT ISN’T WORKING

A clearer direction
for your next formulation.

Tell us what you are developing, what needs to improve and where the project stands. We’ll help identify a sensible starting scope.

Have your project brief handy.
Detailed documents can follow once scope and confidentiality arrangements are agreed.