Manufacturing work is invisible; the results are documented.

Client names stay under NDA, so these are written as project notes: the brief, the constraint that made it difficult, what we changed, and what shipped. Figures are representative of the project scope.

Three briefs, three different constraints.

Each project started with a constraint that ruled out the obvious route — sugar-free texture, a low pilot volume, or a halal gelatin supply chain. The useful part is how the constraint was solved.

UK · Pharmacy · Sleep

A sugar-free sleep gummy that still tasted like a gummy.

A UK pharmacy own-label range needed a 60-count sleep gummy for adults, sugar-free, pectin-based, with melatonin at a pharmacy-appropriate dose and a two-year shelf life.

FormatPectin gummy, 60ct

MOQ5,000 pilot / 40,000 repeat

Lead time18 working days

Constraint

Sugar-free pectin gummies typically lose chew and collapse in warm storage. The first bench trials were either chalky or too soft to demould at line speed.

What we changed

We rebuilt the humectant system, switched to a slower-set pectin and ran a 40°C / 75% RH accelerated study before locking the recipe. Three iterations, each tasted by the client's panel.

What shipped

Pilot of 5,000 units shipped, followed by a 40,000-unit repeat at 18 working days. The client added a second flavour eight months later without changing the base.

US · DTC · Beauty

A collagen stick pack built for a 1,000-unit launch.

A US direct-to-consumer brand wanted a marine collagen stick pack, 5 g dose, neutral taste, to test the market before committing to a tub format.

FormatStick pack, 5 g

MOQ1,000 units

Lead time12 weeks brief to launch

Constraint

The pilot volume was below the economical run for most stick lines, and the brand needed retail-quality artwork on a tight timeline.

What we changed

We ran the pilot on a shared line with a dedicated clean-down, supplied a low-MOQ label plan, and matched the powder to a 5 g fill with a 12-month stability pack.

What shipped

1,000 units shipped for the launch, then 12,000 units on the first repeat. The brand kept the same powder specification when it added a tub six months later.

Gulf · Halal · Softgel

A halal fish-oil softgel with a supply chain that could be documented.

A Gulf distributor needed 1,000 mg fish-oil softgels, halal-certified, in a 30-count bottle for pharmacy and supermarket retail.

FormatSoftgel, 1,000 mg

MOQ30,000 units

Lead time22 working days

Constraint

The gelatin shell, the oil refining aids and the flavour all had to be halal-compliant, and the distributor needed certificates per SKU, not a generic site letter.

What we changed

We mapped every input against the certifier's standard, changed the shell gelatin source, and scheduled the run after a dedicated line clearance. The certificate was issued against the finished SKU.

What shipped

30,000 units shipped in 22 working days, with the halal certificate and COA released together. The distributor added a 60-count pack on the next order.

Client names, exact formulas and commercial terms are withheld. If you need a reference in your category, ask — where an NDA allows, we will arrange a direct conversation.

What determined the outcome.

One constraint at a time

We isolate the variable that can kill the project — texture, fill weight, certification, lead time — and solve it before scaling anything.

Data before opinion

Accelerated stability, fill checks and analytical results decide whether a sample is ready, not how it looks in a photo.

A named owner

Each project has one person accountable from brief to shipment. You do not re-explain the brief to a new department every week.

Manufacturing work is invisible; the results are documented.

Three briefs, three different constraints.

A sugar-free sleep gummy that still tasted like a gummy.

A collagen stick pack built for a 1,000-unit launch.

A halal fish-oil softgel with a supply chain that could be documented.

What determined the outcome.

One constraint at a time

Data before opinion

A named owner

Have a product in mind?