Scaling a Powdered Drink: The Changes Between Small-Batch to Large-Scale Production
Launching a new nutritional powdered drink can be exciting but producing it consistently at a larger scale is something else entirely.
For newer brands looking to grow, a small batch can be a great way to test a formula and consumer demand, but as the demand for orders grow, the manufacturing process becomes less complex, but it requires a strong understanding of the potential changes made to the process, and the right nutritional drink powder manufacturer to see it through.
Finding the Right Method for Scaling the Batch
It may seem like simple math with just multiplying the ingredients to create a bigger batch. The formulas may contain various ingredients that offer different particle sizes, density, and requirements for processing. What may work in a small blender may not behave the same way in a large industrial blender.
When scaling a batch, it’s important to embrace repeatability to ensure that you’re producing the same product, because a small inconsistency can make a huge difference in the product quality and could eventually become an issue with overall production.
Factors to Focus on with Scaling Batches
There are a lot of moving parts that revolve around scaling your product. You’ll need to work with an experienced partner that knows the process and methods to successfully scale a product to ensure that taste, quality, and efficacy remain consistent. These steps include:
Strategic Ingredient Sourcing
Sourcing raw materials for larger batches could lead to supply issues, so having a manufacturing partner with sourcing relationships may come in handy if your original supplier can’t meet the new demands. Qualifying multiple sources for each ingredient and packaging component is also key.
Experience in Mixing
Going from a small batch blender to larger industrial blenders can yield different results. The formula may require some tweaking to ensure that it remains consistent with smaller batch results. Experienced manufacturers understand the behavior of formulations during scale-ups and can anticipate challenges.
Quality Control Becomes Priority #1
Because you’re making larger batches, if quality is compromised, it can result in a few issues. It can lead to severe consequences and lead to a major financial loss. Large-scale manufacturers have quality systems throughout every stage of the process and can incorporate those into every step to ensure that the raw materials, the blend, the documentation, and even the packaging meet FDA 21 CFR 111 Regs – cGMP’s for manufacturing, packaging and holding of dietary supplements.
Updating the Packaging
Small batches usually require smaller pouches or packets. When you increase the volume, it may mean upgrading your packaging as well. This is not only for sales, but also for factors like pallet configuration, case packing, and any other distribution requirements when you go for a larger order.
When to Think About Scaling Your Product
You’ll want to scale your product for when the time is right. There are plenty of factors to consider, but demand seems to be key indicator. But you’ll need to anticipate this, not react to it. A period of time with a lengthy production schedule can result in empty shelves or “out of stock” signs that can hurt your brand’s success.
Partner with the Right Nutritional Drink Powder Manufacturer
When the time comes where your small batch is starting to grow, and your need production to align with demand, partnering with an experienced manufacturer that can assist you with the growth is imperative.
COMMAND Nutritionals has more than five decades of experience with nutritional powdered drink brands with taking small scale batches to larger productions. If you’re in the process of trying to scale your formulation to meet the growing demand, COMMAND Nutritionals can help.
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