Whether you're looking to launch a sleep drink, greens blend, or protein-plus powder, developing a custom powdered food supplement offers unique challenges — and some key considerations. Here's what to expect at each stage — including potential development costs.

1. Defining the Product Brief

Before engaging on your project, it’s essential to have clarity on:

• Target Function (e.g. Sports Nutrition, Sleep, Gut, Immunity)
• Audience (Adults, Menopausal, Active Lifestyle etc.)
• Daily Dose Format (Sachet, scoop, stick-pack)
• Key Ingredients (e.g. Magnesium Glycinate, Ashwagandha, whey protein, electrolytes)
• Desired Claims (e.g. “Contributes to psychological function” – EFSA-approved only)
• Natural vs. Flavoured Profile (e.g. Vanilla, Berry, Citrus)

We recommend including mandatory exclusions (e.g. sugar, maltodextrin, synthetics) and suitability goals (Vegan? No allergens?) from the outset.

2. Ingredient Compliance & Legal Checks

At Nutribl, all formulas are screened against UK legislation, including:

• UK Novel Food Catalogue
• Food Supplements (England) Regulations 2003
• Annex II permitted vitamin/mineral forms
• MHRA Borderline Product Guidance (to avoid medicinal risk)

Ingredients that are standardised extracts (e.g. “20:1 Chamomile”) or synthetic amino acids (e.g. L-Theanine not from tea) are flagged as potential novel foods or medicinal risk — meaning they could block your product from legal sale.

Important: Just because something is “natural” or sold abroad doesn’t mean it’s legal in the UK.

3. Flavour System Development

Powders — especially those containing magnesium, amino acids or bitter botanicals — often need careful flavour balancing. Development includes:

• Taste masking (e.g. of Ashwagandha or Glycine)
• Natural sweeteners (e.g. Stevia, Monk Fruit)
• Acidity and pH balancing (e.g. Citric or Malic Acid)
• Sensory enhancements (e.g. natural berry, vanilla, honey lemon)

This phase is essential for consumer compliance and repeat purchase.

4. Solubility & Functional Testing

A beautiful flavour is worthless if the product doesn't dissolve well.

Common issues:

• Gritty texture (e.g. from magnesium forms)
• Layering/separation
• Foaming or clumping
• Poor flow in sachets or tubs

For custom formulas it is prudent to perform solubility trials, flowability testing, and hygroscopicity checks. These tests help ensure:

• Smooth mixing in cold/warm water
• Consistent scoop weight
• No caking over shelf life

5. Developments Costs: What You Might Need to Pay?

Development costs vary depending on your formula’s complexity. Here’s a general breakdown for custom powder products on a per product basis:

6. Production Readiness: From Sample to Shelf

Once a flavour variant is approved and stability confirmed:

✔ Nutribl finalises label text and confirms claims compliance

✔ Client approves final specs and packaging artwork

✔ First production run scheduled (lead time: usually 6-10 weeks)

We then deliver a ready-for-market label with a full compliance report — ensuring legal defensibility and brand integrity.

Summary: What to Budget and Plan

Total NPD budget range: £1,000–£3,000+ depending on complexity

Product production budget: It is impossible to give an accurate assessment of cost for a product without knowing what is going in it. For custom formulas the MOQ is at least 200kg of powder and based on this you are likely looking at a further capital requirement of £6000 - £15000 depending on ingredients and packaging. This is additional to your development fees.

Factors that influence the production costs:

• Ingredient Complexity: Rare or branded ingredients can increase costs.
• Packaging Choices: Custom or premium packaging options are more expensive - pre-printed pouches will severely impact this.
• Batch Size: Larger batches can reduce per-unit costs due to economies of scale.
• Testing Requirements: Additional testing or certifications adds to costs.

Want to Start Your Powder Project?

We can guide you from concept to scoop — ensuring your product is not only delicious and effective, but legally marketable in the UK.