Custom Supplement Formulation & Manufacturing Services
Gensei Global partners with dietary supplement brands to engineer, optimize, and scale proprietary custom formulas. From active ingredient standardization and excipient compatibility screening to benchtop prototyping, analytical testing, and commercial production, we translate your product brief into a shelf-ready supplement.
Every custom project begins with a confidential technical review to align formulation specs, sampling milestones, and target unit economics.
Start with Your Existing Formula, a Reformulation, or a New Concept
Select the R&D engagement model that matches your current technical stage. Our formulation scientists bridge the gap between your product brief and a commercially manufacturable Master Manufacturing Formula (MMF).
Manufacture an Existing Formula
Already have a finalized Supplement Facts panel or bill of materials (BOM)? We audit raw material grades, bulk densities, and machinability to transition your formula smoothly into commercial production.
Upgrade or Reverse-Engineer
Need to improve organoleptic flavor profiles, switch to clean-label excipients, enhance bioavailability, or benchmark an existing market leader? We refine physical and sensory performance before scale-up.
Develop from a Product Brief
Starting from a health category or target claim? Our R&D team proposes synergistic active ingredients, selects the optimal delivery format, and executes a structured benchtop sampling plan.
Looking for faster speed-to-market using pre-validated base formulas? Explore our Fabrico de suplementos de marca própria catalog.
Engineering a Formula Built for Commercial Scale
A paper Supplement Facts panel does not automatically translate into a stable, manufacturable product. Our R&D team evaluates physicochemical compatibility, active loading limits, organoleptic profile, and downstream machinability before locking your specification.
Assay, Potency & Overages
Verify raw material standardization, bulk and tapped density, hygroscopicity, chemical interactions, and scientific input overages to support shelf-life potency claims.
Fill Capacity & Compressibility
Calculate exact active-to-excipient ratios to fit Size 00/0 capsules, direct-compression or wet-granulated tablets, stick packs, or oil-suspension softgels.
Taste Masking & Dispersion
Optimize bitter-blocking flavor systems, natural sweeteners, mesh particle distribution, moisture barriers, and water activity control.
Machinability & Cost Fit
Align benchtop prototypes with high-speed rotary encapsulation or tableting parameters, clean-label excipient preferences, and target unit economics.
Proactive feasibility engineering identifies potential formulation bottlenecks early—allowing our technical team to propose practical excipient adjustments or multi-unit serving strategies aligned with your target market.
Five Structured Stages from Concept to Commercial Batch
Each development phase concludes with a documented technical milestone, giving your product team full visibility before committing to commercial tooling and bulk raw material procurement.
Brief & Feasibility Audit
Share your target market, desired health positioning, active ingredients, serving size, and target price point. Deliverable: Technical feasibility assessment, format recommendation, and R&D project scope.
Formulation & Excipient Design
Our formulation chemists calculate botanical standardization ratios, active overages, flow agents, or flavor systems. Deliverable: Draft Master Manufacturing Formula (MMF) and preliminary cost-per-unit estimate.
Benchtop Prototyping
We compound lab-scale trial samples to evaluate sensory profile (taste, aroma, mouthfeel), color, disintegration, and physical uniformity. Deliverable: Physical prototype samples shipped for your team's evaluation.
Iterative Refinement & Sign-Off
Fine-tune sweetness, acidity, tablet hardness, or capsule shell selection based on your feedback and establish analytical QC criteria. Deliverable: Signed-off Final Product Specification (FPS) and quality testing protocol.
Commercial Scale-Up & QC Release
Transition the approved formula into raw material procurement, cGMP batch blending, high-speed filling, packaging, and analytical release. Deliverable: Commercial production run, batch traceability records, and Certificate of Analysis (COA).
Sampling timelines, included revision rounds, and R&D credit-back policies toward commercial orders are clearly itemized in your project proposal.
Choose a Delivery Format Engineered for Your Formula
Dosage form selection balances total active loading per serving, ingredient stability, consumer compliance, and target unit cost. Explore our dedicated manufacturing lines by format:
Cápsulas duras
Precision powder and beadlet blends engineered for consistent fill weight and flowability in HPMC vegetarian, pullulan, or gelatin shells (Size 000 to Size 2).
Capsule Manufacturing ↗Comprimidos comprimidos
High-load direct compression and wet-granulation formulas with customizable punch tooling, bisect scoring, and aqueous film or enteric coatings.
Tablet Manufacturing ↗Chewable & Effervescent
Organoleptically balanced chewable and dissolvable tablets formulated for controlled hardness, smooth mouthfeel, and rapid disintegration.
Chewable Tablet Manufacturing ↗Misturas em pó
High-serving functional blends (collagen, proteins, electrolytes, greens) engineered for instant dispersion, bitter-masking, and anti-caking stability.
Powder Manufacturing ↗Cápsulas de gelatina mole
Hermetically sealed oil-based solutions and botanical suspensions paired with tailored bovine/fish gelatin or plant-based vegetarian shell matrices.
Softgel Manufacturing ↗Functional Gummies
Pectin and gelatin gummy systems formulated to balance heat-sensitive active retention, water activity control, texture, and low-sugar profiles.
Gummy Manufacturing ↗Reference Commercial Benchmarks by Format
Lab-scale R&D prototyping is scoped independently from commercial batch minimums. The benchmarks below reflect typical commercial production parameters once your custom specification is approved.
| Dosage Format | Reference Production MOQ | Benchtop Prototype Window | Commercial Production Lead Time |
|---|---|---|---|
| Misturas em pó | 100 kg per formula / flavor | 100–300 g lab sample; ~2 weeks | Indicative 4–6 weeks ex-factory after material & packaging readiness |
| Tablets & Chewables | 100,000 tablets / SKU | ~2–3 weeks for uncoated or flavored trial samples | Indicative 6–8 weeks after prototype sign-off and raw material arrival |
| Cápsulas duras | 100,000 capsules / SKU | ~7–15 working days for fill-weight & shell prototyping | Indicative 6–8 weeks, subject to specialty ingredient lead times |
| Cápsulas de gelatina mole | 100,000 softgels / SKU | ~2–4 weeks for fill-suspension & shell compatibility trials | Indicative 6–8 weeks following technical & stability approval |
| Functional Gummies | 150,000 – 300,000 gummies / SKU | ~2–4 weeks for kitchen-batch flavor, brix & texture trials | Indicative 6–8 weeks after mold, flavor, and stability sign-off |
Analytical Verification, Confidentiality & Formula Ownership
Every custom formulation project transitions from benchtop R&D to commercial production under rigorous quality documentation and contractual intellectual property safeguards.
Analytical QC & Production Handoff
- Master Manufacturing Formula (MMF) and finished-product specifications
- Raw material identity, active potency (HPLC / UV), and heavy metal (ICP-MS) verification
- In-process physical checks (weight variation, disintegration, hardness, friability, water activity)
- Microbiological screening (USP / ISO protocols) and full batch traceability records
- Batch-specific Certificate of Analysis (COA) issued prior to commercial release
NDA & Intellectual Property Framework
- Mutual NDA Protection: We execute Non-Disclosure Agreements prior to reviewing proprietary ingredient ratios or confidential R&D concepts.
- Clear Formula Ownership: Client-supplied formulas remain client IP; ownership and exclusivity of newly developed custom formulas are formally defined in writing.
- Transparent R&D Fee Structure: Lab prototyping fees, included sample revision rounds, and bulk-order credit policies are itemized upfront.
- Regulatory Dossier Support: Technical data sheets (TDS), allergen declarations, and export certificates are compiled to support your target market compliance.
Quality Management & Facility Credentials
Access our core quality management and dietary compliance certificates below for your initial vendor qualification review. Complete audit packages, cGMP compliance documentation, and product-specific declarations are provided during onboarding.
Batch-specific COAs, third-party laboratory test reports, and destination-market export documentation are configured per project specification.
Custom Supplement Formulation FAQ
Answers to key technical and commercial questions from supplement brand founders, R&D directors, and procurement managers.
Can we bring our own existing formula or Supplement Facts panel?
Yes. Share your existing bill of materials (BOM), target active potencies, and preferred dosage format. Our formulation engineers review bulk density, excipient compatibility, and machinability before preparing your commercial quotation.
Can Gensei develop a custom supplement formula from scratch?
Yes. Provide your target health positioning, hero ingredients, flavor preferences, and target cost per unit. We design a compliant formulation architecture, recommend optimal delivery formats, and outline a structured benchtop sampling plan.
How do you determine if our target dosage fits a capsule, tablet, or powder?
Dosage fit depends on raw material standardization grades, bulk and tapped density, required excipients, and moisture sensitivity. During our initial feasibility review, we calculate exact fill weights and recommend whether a single unit, multi-capsule serving, tablet, or powder blend best fits your label claims.
What are the MOQs and lead times for custom supplement manufacturing?
Reference commercial MOQs start at 100 kg for custom powders, 100,000 units for standard capsules, tablets, or softgels, and 150,000–300,000 pieces for functional gummies. Benchtop R&D samples typically take 2–4 weeks, while commercial production runs generally require 4–8 weeks after prototype and packaging approval.
How do prototype sampling and flavor or texture revisions work?
Once the paper formula is approved, we compound benchtop prototypes for your physical and sensory evaluation. Your R&D proposal specifies the included revision rounds to fine-tune sweetness, flavor masking, mouthfeel, or tablet coating prior to pilot scale-up.
How do you protect our intellectual property and formula ownership?
We gladly execute a mutual Non-Disclosure Agreement (NDA) before you share proprietary formulation data. Client-supplied formulas remain your exclusive property, and IP ownership Rights for newly developed custom formulations are clearly defined in your manufacturing agreement.
What details should we include when requesting a formulation review?
Include your destination market, product category, target active ingredients with approximate dosages per serving, preferred dosage format, packaging style (bottles, pouches, blisters, stick packs), and estimated launch volume.
Request a Custom Formula Feasibility Review
Submit your project brief for a confidential technical and commercial assessment with our R&D engineering team.
- Existing Supplement Facts panel, reformulation goals, or new product concept
- Target active ingredients and desired potency per serving
- Preferred dosage format, packaging type, and destination market
- Estimated launch quantity and target timeline
Formulação personalizada de suplementos & CDMO Manufacturing
sales@collagensei.com
Send Your Custom Formula Project Brief
Share your formulation specifications or concept below. Our technical team typically responds within 1 business day with initial feasibility feedback and next steps.
Ready to evaluate your custom formula? Send your ingredient list or product brief directly to our R&D and technical sales team.
Contact Our Formulation Team ↗