Custom-Shaped Gummy Manufacturer for Retail and Private Label

Custom shapes start with a drawing, 3D file or physical sample. Our tooling team reviews wall thickness, undercuts and demoulding angles before cutting a cavity. Simple shapes move to sample in 7–10 working days. Complex multi-cavity or 3D relief designs add 5–7 days for tooling. We hold a standard library of bears, stars, hearts, bottles, coins and fruit slices for brands that need speed over exclusivity. Each cavity is tested on the depositor to confirm fill weight and release.

The plant runs multiple depositing lines with changeover between shapes under 4 hours. That keeps pilot runs practical at 1,000 units and full runs efficient at 50,000 units or more per SKU. We bottle in 30, 60, 90, 120 and 180 count PET or HDPE, with induction seals, child-resistant caps and desiccant where needed. Labels are applied in-house. If you already work with a gummy manufacturer, custom shapes are the usual next step after a standard bear or star.

Shape affects texture. Thin ears, tails or points cool faster and can become brittle. We adjust gelatin bloom, pectin grade and moisture target to match the cavity. Typical fill weights run 1.5 g to 5.0 g. Actives are dosed by weight, not volume, so a 500 mg vitamin C gummy in a star shape delivers the same load as a bear. Common actives include vitamins C, D3, B12, zinc, elderberry, melatonin, collagen, biotin and probiotic blends.

Sugar-free options use maltitol, sorbitol or allulose. Vegan options use pectin or modified starch. Sugar-coated and sour-sanded finishes are available for custom shapes, though fine details can be softened by a coating. We run flavour and stability trials before mass production. If an active is heat-sensitive, we adjust slurry temperature and hold time. Every formula is documented with a master batch record, specification sheet and COA template.

The facility is GMP-certified and FDA-registered. We hold ISO 22000 and HACCP, with halal and vegan certification available per SKU. Incoming raw materials are tested for identity, potency and heavy metals. Finished gummies are tested for weight, hardness, moisture, microbiology and active content. Retention samples are kept for shelf life plus 6 months. Batch records are traceable from raw material lot to finished bottle.

Export documentation covers US, EU, UK and Middle East markets. We provide COA, MSDS, free sale certificate, halal certificates and origin documents. Shipping runs FOB Shenzhen or Yantian, with air freight for pilot runs. Typical sea transit is 18–28 days to US west coast, 25–35 days to EU ports. We can palletise and label to your warehouse requirements. Lead time for mass production is 20–35 working days after sample approval.

Every custom-shaped gummy batch is sampled at three points: incoming raw materials, in-process gel and finished product. Identity testing confirms the active ingredient by HPLC or UV-Vis against a reference standard. Potency is assayed to ensure the label claim falls within 90–110% for vitamins and 95–105% for botanicals. Microbial testing covers total aerobic count, yeast and mould, E. coli, Salmonella and Staphylococcus aureus. Heavy metals (lead, arsenic, cadmium, mercury) are tested by ICP-MS. Disintegration testing follows USP <2040> for gelatin and pectin bases to confirm the gummy breaks down within the specified time.

A Certificate of Analysis (COA) is issued for each batch and includes the batch number, production date, expiry date, active ingredient content, microbial results, heavy metal results, disintegration time and a statement of conformity to the agreed specification. Retention samples from every batch are stored under controlled conditions (20–25°C, 60% RH) for the shelf life plus six months. Stability studies follow ICH Q1A(R2) guidelines with accelerated conditions (40°C/75% RH) for six months and real-time testing at 25°C/60% RH for up to 24 months. These data support the expiry date printed on your retail packaging.

Custom shapes can affect disintegration and potency uniformity because cavity geometry influences cooling rates and active dispersion. We therefore run a uniformity test on ten gummies per batch, measuring weight variation (target ±5%) and active content uniformity (acceptance value ≤15). If your formula includes heat-sensitive actives such as probiotics or certain enzymes, we adjust the depositing temperature and may recommend a pectin base over gelatin to reduce thermal exposure. All testing is performed in-house or at accredited third-party laboratories, and results are traceable to the batch record.

Custom-shaped gummies can be packed in HDPE bottles (60, 90, 120 or 180 count), blister packs, stick packs or single-serve sachets. Bottles are induction-sealed and fitted with child-resistant or standard caps depending on market requirements. For Amazon and retail, we apply FNSKU labels, lot codes and expiry dates in the format you specify. Cartons are printed with your artwork and can include a nutrition panel, supplement facts panel, allergen statement and country of origin. We provide dielines and label templates that meet FDA 21 CFR 101.36 for dietary supplements, including the required 'Supplement Facts' box and ingredient listing.

Lot and expiry coding is applied at the filling line using inkjet or laser coding. We retain a coding record for each batch so that any recall can be traced to the exact production window. Carton specifications: 250–350 gsm kraft or white board, with dimensions matched to your bottle count. Standard export cartons hold 12, 24 or 48 bottles and are palletised at 1,000–1,200 kg per pallet with stretch wrap and corner boards. For Amazon FBA, we can print and apply FNSKU labels, poly-bag units and prepare cartons to Amazon's ISTA-6 requirements.

Retail readiness also covers barcode verification (GS1-128 or UPC-A), country of origin marking and, for the EU, the address of the responsible person. We do not print claims such as 'FDA approved' or 'cures' because these are not permitted for dietary supplements. Instead, we review your label text against the permitted structure/function claims and flag any wording that may require a disclaimer. If you sell in multiple markets, we can produce market-specific labels from the same batch, provided the label approval is completed before production starts.

The MOQ for a custom-shaped gummy is 1,000 units per SKU, with lower quantities available for pilot runs (typically 1,000 units) to support market testing. Sample lead time is 7–10 working days from receipt of your 3D file or drawing and approved formulation. The sample includes a preliminary COA and a packaging mock-up. Once you approve the sample, mass production takes 20–35 working days, depending on the complexity of the shape, the number of actives and the packaging format. We provide a production schedule at order confirmation and update you at key milestones.

Shipping options include air freight (5–10 days door-to-door) and sea freight (25–40 days port-to-port). We quote EXW, FOB Shenzhen or DDP depending on your preference. For DDP, we handle customs clearance and delivery to your warehouse, but you remain responsible for import compliance in your market. Documents provided with each shipment include the commercial invoice, packing list, COA, MSDS (where applicable), free-sale certificate and, for certain destinations, a phytosanitary certificate or certificate of origin. We do not provide a halal certificate unless the batch is produced under that certification scheme.

For repeat orders, we keep your mould and label artwork on file, which reduces set-up time and cost. Lead times for repeat orders are typically 15–25 working days. If your order is time-sensitive, we can arrange partial air shipments to bridge the gap while the sea freight is in transit. All shipments are palletised and shrink-wrapped, with desiccant added for humid destinations. We recommend booking sea freight at least six weeks before your retail launch to allow for customs clearance and inland delivery.