Developing a new cosmetic or personal care product starts with turning an idea into a formulation that can be sampled, reviewed, tested and eventually manufactured at commercial scale.
For brands without an in-house formulation team, R&D support can help guide the product from an initial brief through formulation development and refinement.
At Delta, formulation is considered as part of the wider product development and manufacturing process. This means the requirements of future testing, scale-up and production can be considered while the product is still being developed.
What Are R&D Formulation Services?
R&D formulation services support the development of new cosmetic and personal care products, as well as the refinement of existing formulations.
A brand may come to the development team with a detailed product brief, an existing formulation or an early-stage product idea.
The formulation process then works through what the product needs to achieve, how it should feel and what needs to be considered before it can progress towards commercial manufacturing.
This may include:
- Product concept and brief development
- Ingredient selection
- Formulation development
- Lab samples and refinement
- Relevant product testing
- Scale-up and manufacturing preparation
The exact process will depend on the product and how far the brand has already progressed.
Starting With the Product Brief
A clear product brief gives the formulation team a starting point for development.
It may include:
- Product type and format
- Intended product benefits and claims
- Ingredient preferences or exclusions
- Desired texture and finish
- Fragrance preferences
- Packaging direction
- Target cost
- Intended market
Some brands arrive with very specific requirements. Others need more guidance to turn an initial idea into a workable brief.
Both can be valid starting points.
The important part is understanding what the finished product needs to achieve before formulation development begins.
From Brief to Lab Sample
Once the product direction is understood, the formulation team can begin developing the first version of the product.
Ingredient decisions are made as part of the complete formulation rather than one ingredient at a time. The team may need to consider factors such as the desired product experience, intended claims, ingredient compatibility, cost, availability and future manufacturing requirements.
An initial lab sample is then prepared for the brand to review.
Feedback may relate to areas such as:
- Texture
- Appearance
- Fragrance
- Spreadability
- Absorption
- Overall product feel
It is common for a formulation to go through several rounds of refinement before it is ready to move forward.
Clear feedback during this stage helps the formulation team understand what needs to change between samples.
Testing During Product Development
Testing can provide information about how a formulation is performing and whether further development work may be needed.
The testing program will depend on the individual product.
Where relevant, this may include:
- Stability testing
- Microbial testing
- Preservative efficacy testing
Other product-specific testing may also be required depending on the formulation, intended use and regulatory pathway.
Testing should be considered as part of product development rather than treated as the final step before manufacturing.
If results show that further work is required, the formulation can be reviewed before the product progresses.
Considering Regulatory Requirements
Regulatory requirements can influence formulation decisions, particularly when a brand intends to sell in more than one market or is developing a product that may fall within a regulated category.
What needs to be considered will depend on the product, its ingredients, intended claims and where it will be sold.
Knowing the intended market early can help the formulation team consider requirements that may affect development.
Where specialist regulatory advice or market-specific submissions are required, these may need to be managed by the brand or an external regulatory specialist.
Moving From R&D to Manufacturing
A formulation developed at lab scale still needs to be transferred into a commercial manufacturing process.
Lab samples and commercial batches are produced at very different volumes and using different equipment.
Once the formulation reaches the appropriate stage, the manufacturing process can be developed and, where required, a pilot-scale batch may be used before commercial production.
Considering manufacturing requirements during formulation can make the transition from development to production more straightforward.
This is one of the advantages of working with a formulation and manufacturing partner rather than developing the formula separately from the business that will eventually produce it.
Why Work With a Formulation and Manufacturing Partner?
Product development involves more than creating a sample that looks and feels right.
The formulation also needs to progress through the relevant testing and be suitable for commercial manufacturing.
Having formulation and manufacturing teams connected within the same process means production requirements can be considered earlier.
For brands, this can also reduce the number of handovers between suppliers as the product moves from the initial concept through development and into manufacturing.
R&D and Formulation at Delta
Delta works with cosmetic and personal care brands from early formulation development through to commercial manufacturing.
Depending on the project, Delta can support:
- Product brief and formulation development
- Ingredient selection and formulation refinement
- Lab samples
- Stability testing
- Microbial testing
- Preservative efficacy testing
- Scale-up where required
- Commercial manufacturing, filling and packing
The development process will vary depending on the product, its requirements and how much work has already been completed before the project reaches Delta.
When Should a Brand Speak to a Formulation Partner?
Brands can involve a formulation partner at different stages.
Some begin the conversation with an early product idea. Others already have a detailed brief or an existing formulation they want to manufacture or refine.
Speaking with the development team before packaging, claims or launch dates are fully locked in can give the project more flexibility while the formulation is being developed.
The formulation team can then help identify what needs to be resolved early and what can continue to evolve as the product progresses.
Ready to Develop a Cosmetic or Personal Care Product?
Delta works with brands from formulation development through to commercial manufacturing.
Speak to Delta about your product idea, formulation requirements and the next steps towards manufacturing.