Knowing whether a formula can be industrialised is essential for several key reasons in the cosmetics, agri-food, pharmaceutical and other sectors that design products intended for large-scale manufacture. Do you know the main steps to industrialise a formula?
Here are the first three key steps to industrialise a formula
✅ 1. Verification of raw materials
Before even testing production, you must ensure that:
• the raw materials are available in industrial quantities;
• they are stable and transportable;
• they are available from several suppliers (to avoid shortages);
• the prices are compatible with the target cost of the product.
👉 A formula may be excellent… but unsellable if a rare ingredient is too expensive.
✅ 2. Technical feasibility study
We analyse whether the formula can be manufactured using the factory’s resources:
• Is the manufacturing temperature accessible?
• Is the heating or stirring time reasonable?
• and is the equipment suitable (tanks, pumps, filters, homogenisers, etc.)?
• Are there any corrosive materials or materials that are incompatible with the equipment?
• Are there any specific steps that cannot be carried out on a large scale?
Example: an emulsion that requires 3 hours of homogenisation may not be industrially viable.
✅ 3. Pilot tests (scale-up)
This is the key phase: going from 100 g in the laboratory to 10 kg, then 100 kg, then 1 tonne. We observe:
• changes in texture or viscosity;
• the appearance of bubbles, foam or separation;
• changes due to scale-up (slower heating, different shear).
👉 Many formulas that are ‘perfect’ in the laboratory fail at this stage and have to go back to ‘development’.
The following four steps must also be taken to industrialise a formula
✅ 4. Stability analysis
The formula must remain stable over time:
• hot/cold cycles,
• centrifugation,
• accelerated ageing,
• microbial contamination.
If the product separates, oxidises or hardens → industrialisation is impossible until the formula is adjusted.
✅ 5. Regulatory compliance
We check that:
• all ingredients are authorised,
• their percentages comply with regulations,
• the mandatory tests can be carried out (toxicology, challenge test, etc.).
👉 A formula may be technically Ok but illegal to sell.
✅ 6. Cost validation
We calculate:
• material cost,
• production cost (machine time, energy),
• possible rejection rate,
• desired margin.
Industrialisation must be profitable, not just feasible.
✅ 7. Final validation (industrial test batch)
A first complete industrial batch is manufactured to verify:
• reproducibility,
• quality of the finished product,
• compliance with technical specifications,
• actual production time.
If everything is compliant → the formula is officially ready for industrialisation.
CONCLUSION
A formula is only valuable if it can be reproduced reliably, securely, compliantly and cost-effectively on a large scale. That is why validating its industrialisation (via the seven steps) is essential before any product launch.
If you want to work with experts to industrialise your formula, call on our services
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