How to Design a Custom Gummy: From Brief to Bottle

The base determines texture, vegetarian status and how much active you can load. Gelatin gives a firm, springy chew and holds actives well, but rules out vegan claims. Pectin gives a softer, shorter bite and is fully plant-based; it needs a higher solids content and tighter pH control, typically 3.2–3.6. Starch-moulded gummies suit high-dose actives but have a chalkier mouthfeel. Most retail brands launching in the US or EU now choose pectin for the vegan label, accepting a slightly higher unit cost.

Format follows the base. A 2.0 g piece suits a single low-dose active such as 5 mg melatonin or 25 mg CBD. A 4.5 g piece can carry 500 mg of a bulky ingredient such as apple cider vinegar, though taste masking becomes the limiting factor. Dosing is usually 1–3 gummies per day, which sets your label serving size and your per-bottle count: 60, 90 or 120 pieces in a 200 ml or 250 ml PET or HDPE bottle.

Active loading is the hardest constraint. Water-soluble ingredients disperse cleanly. Oil-based actives such as omega-3, vitamin D3 or CBD need emulsification, and heat-sensitive vitamins need overage. Vitamin C at 250 mg per gummy will lose roughly 10–15% across a 24-month shelf life, so you formulate above label claim. Probiotics are more delicate: only spore-forming strains such as Bacillus coagulans reliably survive the cooking step, and you should expect 0.5–1 log loss during production.

Sweetener systems shape both taste and label. Sucrose and glucose syrup give the cleanest flavour but add 2–4 g of sugar per piece. Maltitol and sorbitol cut sugar to near zero but cause laxative effects above roughly 20 g per day. Allulose and erythritol with stevia or monk fruit now dominate sugar-free launches. Sourness comes from citric, malic or fumaric acid; bitterness from actives is usually masked with a fruit flavour blend plus a 0.1–0.3% salt or sucralose addition. Always taste a sample before approving the formula.

Compliance starts with the destination market. In the EU, gummies are usually sold as food supplements under Directive 2002/46/EC, so claims must sit on the EU Register. In the US, structure-function claims need the standard disclaimer. Halal certification requires a gelatin source acceptable to the certifying body, or a pectin base. Organic claims require USDA or EU organic certification of every ingredient above 5% of the formula, and the facility must hold the corresponding certificate.

Testing and logistics follow. Budget for finished-product tests: microbiological, heavy metals, and potency at 0, 12 and 24 months if you want a real shelf-life claim. Stability studies usually run 3–6 months accelerated. Packaging lead time sits outside production: bottles, caps and labels add 15–25 working days if sourced new. Air freight from Guangdong to the US or EU takes 5–8 days; sea freight 25–35 days. Build both into your launch date before you approve the formula.

Every custom gummy batch is tested against a written specification before release. Incoming raw materials are checked for identity and potency: pectin or gelatin bloom strength, sweetener assay, and active ingredient certificate of analysis from the supplier. In-process checks cover weight variation (target ±5%), texture, and colour. Finished-product testing includes active potency (usually by HPLC), microbial limits (total aerobic count, yeast and mould, E. coli, Salmonella), heavy metals (lead, cadmium, arsenic, mercury), and disintegration time. Disintegration is critical for gummies: pectin-based pieces typically dissolve in 30–45 minutes, gelatin in 15–25 minutes, and the test confirms the matrix releases actives as intended.

A certificate of analysis (COA) is issued for each batch and includes the batch number, production date, expiry date, test parameters, specification limits, results, and the analyst's signature. It also states the testing laboratory and method reference. Buyers receive the COA as a PDF within 3–5 working days of batch completion. Retention samples (at least two bottles per batch) are stored under controlled conditions (25°C/60% RH and 30°C/65% RH) for the full shelf life plus six months. These samples are available for third-party verification if a retail buyer requests it.

Stability testing follows a standard protocol: accelerated conditions at 40°C/75% RH for six months, with pull points at 0, 1, 2, 3, and 6 months. Real-time testing at 25°C/60% RH runs concurrently for 24–36 months, depending on the declared shelf life. Parameters tested include potency, microbial count, moisture, texture (hardness), and colour. A stability summary report is provided with the first production batch, and ongoing batches are monitored annually. This data supports the expiry date printed on the label and is often requested by retail chains and Amazon sellers.

For custom gummy projects, the quality control plan is agreed before production. This includes defining critical control points (CCPs) for pasteurisation, water activity (target below 0.65 for shelf-stable gummies), and metal detection. The factory operates under GMP, ISO 22000, and HACCP, and can provide audit reports on request. If a buyer requires additional testing, such as allergen screening or specific pesticide residues, this is quoted separately and adds 5–7 working days to the lead time. All testing is performed in-house or by accredited third-party laboratories, and results are traceable to the batch.

Custom gummies can be packed in several formats: round or square bottles (typically 60, 90, 120, or 180 count), blister packs, stick packs, or single-serve sachets. Bottles are the most common for retail and use HDPE or PET with induction seals and child-resistant caps where required. Blisters suit pharmacy channels and sample packs. Stick packs and sachets are popular for on-the-go formats. The factory can supply stock bottles or work with buyer-supplied packaging. Typical bottle dimensions are 50–75 mm diameter and 100–150 mm height, with label areas sized accordingly. Carton specifications: 12–24 bottles per shipper, with pallet configurations of 48–60 cartons per layer, depending on bottle size.

For the US market, the label must include a supplement facts panel, serving size, active ingredients with quantities, other ingredients, and a manufacturer/distributor statement. The factory provides a label template and reviews buyer artwork for compliance with FDA 21 CFR 101.36. Lot and expiry coding are applied by inkjet or laser on the bottle and carton. Expiry dates are typically 18–24 months from production, supported by stability data. Barcodes (UPC or EAN) are printed or labelled as required. For Amazon FNSKU, the factory can apply the FNSKU label over the barcode or print it directly, provided the buyer supplies the label file.

Retail readiness includes carton marking: lot number, expiry date, quantity, and country of origin (China). Pallet specs follow standard GMA or EUR pallets, stretch-wrapped and labelled with SSCC if needed. The factory can provide packaging mock-ups for buyer approval before mass production. For EU markets, the label must include the address of the food business operator and a nutrition declaration. The factory assists with translations but final legal responsibility rests with the brand owner. Packaging lead time is typically 10–15 working days if using stock components; custom bottles or printed labels add 20–25 working days.

The minimum order quantity for custom gummies is 1,000 units per SKU for retail bottling, or from 500 units for a pilot run (hand-packed). Sample lead time is 7–10 working days after receipt of a complete brief and payment of the sample fee. Mass production takes 20–35 working days after sample approval, depending on the complexity of the formulation and packaging. This window includes raw material procurement, production, testing, and packing. If custom packaging is used, add the packaging lead time. The factory provides a production schedule with milestones and shares progress updates weekly.

Shipping options are air freight (5–10 days to major hubs) or sea freight (25–40 days to US/EU ports). Incoterms offered are EXW (factory), FOB (port of loading), and DDP (delivered duty paid) for select destinations. DDP is available for the US, UK, and EU, with all duties and taxes handled by the factory's freight partner. Air freight is typically used for pilot runs or urgent orders, while sea freight is more cost-effective for full containers (20ft or 40ft). The factory provides a packing list and commercial invoice for customs clearance.

Documentation provided with each shipment includes the certificate of analysis (COA), material safety data sheet (MSDS) if applicable, free-sale certificate, and phytosanitary certificate where relevant (for plant-derived ingredients). The factory also provides a certificate of origin and can legalise documents for certain markets at additional cost. For Amazon sellers, the factory can ship directly to Amazon fulfilment centres (FBA) with proper labelling. Lead times for documents are 2–3 working days after shipment. The factory recommends booking shipping space at least two weeks before production completion to avoid delays.