Exploring the Different Phases of Formulation Development

When you see a finished product on the shelf—whether it’s a skincare serum, a nutritional supplement, or a bottled beverage—it may seem like it simply appeared there. But behind that product is a detailed, deliberate journey known as formulation development. This process is essential for bringing any high-quality liquid product to life, and it involves a lot more than mixing ingredients in a lab.

Understanding the phases of formulation development can help brands, manufacturers, and entrepreneurs work more effectively with a contract manufacturer. Whether you're developing cosmetics, supplements, or personal care products, the process is complex—but it doesn’t have to be mysterious.

Let’s walk through the major stages of formulation development and explore what each one involves.

Phase 1 Concept and Feasibility

The process begins with a product idea. Maybe it’s a new line of skincare, a functional wellness drink, or a personalized hair serum. This concept stage lays the groundwork for everything that follows.

Evaluating Product Goals and Requirements

At this point, key questions help guide the direction of the formulation:

• What is the purpose of the product?

• Who will be using it?

• What are the desired ingredients or exclusions (e.g., fragrance-free, paraben-free)?

• Are there specific certifications or claims in mind?

These early decisions affect which ingredients are viable and what regulations might come into play.

Feasibility Review

A qualified contract manufacturer or formulator will evaluate whether the concept is practical, based on available ingredients, cost, regulations, and timeline. This is also where formulation services can help you avoid unnecessary trial and error before development begins. Reviewing customer expectations, market demand, and your own brand vision helps determine if the product is worth pursuing and can be developed efficiently.

Phase 2 Initial Product Formulation

Once the concept is locked in, the team begins formulating. This is where raw ingredients start to become something more functional and structured.

Creating a Baseline Formula

Using specifications and performance goals, chemists begin formulating prototypes. This can include:

• Active ingredients

• Preservatives

• Emulsifiers or thickeners

• Fragrance and colorants (if applicable)

Depending on the type of product, the formulation may also require ingredients that meet organic standards or comply with vegan, cruelty-free, or gluten-free claims. Creating a clean, effective, and market-ready product often requires balancing ingredient availability with consumer trends.

Ingredient Sourcing

It’s critical to use ingredients that are available at scale, cost-effective, and compliant with regulatory guidelines. Contract manufacturers with experience in liquid manufacturing or automated filling services will already have strong supplier relationships. This not only streamlines the process but also reduces the risk of delays or inconsistencies.

Phase 3 Testing and Refinement

No first version is ever final. This phase focuses on ensuring the formula performs well, is stable, and meets compliance standards.

Key Testing Steps

Depending on the product type, testing may include:

• Stability and shelf-life testing

• Microbial and preservative effectiveness testing

• pH and viscosity checks

• Sensory evaluation

Certain formulations, like serums or emulsions, may need to undergo temperature testing to ensure they maintain their consistency and efficacy over time.

Iterating Based on Results

Based on the results, the formulation is often refined multiple times. Something as small as a 0.5% change in a thickener or surfactant can impact texture, feel, or product separation. This is where working with a partner like Automated Filling Services can save time and costs by minimizing trial-and-error through expert guidance. Custom formulation solutions shine here, helping tailor the formula precisely to your brand’s needs.

Phase 4 Pilot Batch Production

With a finalized lab formula, it's time to test how the product performs at a slightly larger scale.

Small-Scale Manufacturing Runs

Pilot batches help determine whether the formulation can be scaled without unexpected changes. It’s a test run before moving into full production.

Small-scale runs also help evaluate the time required for mixing, filling, and packaging—essential data when planning for mass production through automated filling or contract packaging.

Packaging Compatibility

This stage often includes packaging trials to make sure the formula works with the chosen container (e.g., no leaking, separation, or breakdown of materials). Choosing the right container—such as airless pumps for serums or squeezable tubes for lotions—isn’t just about appearance. It directly affects product stability and usability.

Phase 5 Scaling and Compliance

After pilot success, the product is ready to be prepared for full-scale production and sale.

Transitioning to Full Manufacturing

The focus now shifts to production efficiency and consistency. This includes:

• Locking in final ingredient sourcing

• Adjusting batching methods for larger volumes

• Ensuring machinery compatibility (e.g., automated filling or contract filling equipment)

Reliable contract manufacturing partners will already have the infrastructure in place for efficient scale-up, especially for products requiring consistent liquid filling across thousands of units.

Finalizing Compliance Documents

Depending on the market, regulatory documents like safety data sheets (SDS), ingredient declarations, and product testing reports are finalized for submission. For cosmetics, supplements, or over-the-counter items, compliance with FDA, EU, or Health Canada guidelines is a must.

Phase 6 Packaging and Product Launch Prep

With the formula and manufacturing process ready, packaging and branding take center stage.

Labeling and Design

Your product packaging must align with regulatory standards, branding goals, and consumer expectations. This includes ingredient lists, usage instructions, batch codes, and more.

If you’re offering white labeling through a contract manufacturer, your product can be delivered with your branding already in place. This saves time and resources, especially for brands looking to scale quickly or test multiple SKUs.

Launch Readiness

By now, you've completed testing, pilot runs, packaging approval, and compliance. It’s time to get the product into the hands of consumers. A reliable partner offering liquid filling solutions and contract packaging can make this step seamless.

Phase 7 Post-Launch Refinement

Formulation development doesn’t necessarily end at launch. Sometimes, product tweaks or scaling improvements come from user feedback.

Monitoring Market Response

Real-world product usage may uncover minor issues or opportunities for improvement. That could mean adjusting viscosity, improving fragrance, or switching packaging. It also offers insight into potential line extensions or new product formats.

Long-Term Support

A trusted contract manufacturer can help you adapt without starting over. As your business grows, the right partner should offer scalable liquid filling solutions and ongoing support for product formulations.

How Contract Packaging and Liquid Filling Fit In

While the focus is often on the formula itself, how the product is filled, packaged, and shipped is just as important. Automated systems ensure precision and consistency, especially with liquid products. Whether it’s a serum, toner, or supplement, liquid filling must be exact to ensure customer trust and regulatory compliance.

Companies like Automated Filling Services provide automated filling and contract packaging that match the specific needs of each product. This includes custom container selection, labeling, and product protection during transit.

The synergy between high-quality formulation development and reliable packaging makes a noticeable difference in product quality and shelf appeal.

Working with a Contract Manufacturer

Choosing the right contract manufacturer is about more than just mixing ingredients. A strong partner provides expertise, equipment, scalability, and compliance support. When working with complex formulations, especially those that require unique textures, delivery methods, or sensitive ingredients, experience matters.

From custom formulation solutions to white labeling and formulation services, a well-rounded manufacturer helps guide your idea into a successful product.

How Automated Filling Services Supports Formulation Development

Automated Filling Services works with brands of all sizes to support each phase of formulation development, from concept to packaging. With a focus on custom formulation solutions, automated filling, and contract manufacturing, AFS helps turn product ideas into consistent, high-quality finished goods. Check out all the services we can offer your growing business.

If you’re building a new product line or scaling an existing one, let Automated Filling Services guide your journey. Contact us to learn more about how our formulation services and contract filling capabilities can support your success.