A Guide to Cosmetic Product Formulation

A cosmetic formulation lab is where product ideas are developed into formulas that can be sampled, tested and prepared for commercial manufacturing.

At Delta, formulation is considered as part of the wider product development and manufacturing process, alongside testing, scale-up and production requirements.

For founders and product developers in the early stages of creation, working with an experienced formulation and manufacturing partner can make the development process easier to navigate and help identify potential issues earlier.

What Is a Cosmetic Formulation Lab?

A cosmetic formulation lab is an R&D environment where cosmetic and personal care formulas are developed, sampled and refined before moving towards manufacturing.

This is where the product brief starts becoming a real formula that a brand can review and refine. In practical terms, a formulation lab helps answer some of the most important early-stage product questions:

• Which ingredients will deliver the desired benefit?
• Will the formula remain stable over time?
• Can the product be manufactured consistently at scale?
• Are there ingredient, claim or market requirements that need to be considered during development?

Put simply, formulation development takes a product idea and turns it into something that can be sampled, tested, refined and eventually manufactured at scale.

Why Formulation Matters to Product Success

Formulation is one of the most important stages in the product development lifecycle.

Good formulation work creates a stronger starting point for testing, scale-up and manufacturing. It allows areas such as product performance, consistency, stability and manufacturing requirements to be considered during development.

Inside the Delta Formulation Process

At Delta, formulation development is a collaborative process that takes both the product brief and future manufacturing requirements into account.

The aim is not just to create a good lab sample. The formula also needs to be suitable for testing, scale-up and eventual production.

Step 1: Understanding the Product Brief

Every successful formulation begins with a clear understanding of the product vision.

This early stage typically includes:

• Product type and format
• Performance goals and intended claims
• Texture and sensory targets
• Ingredient preferences or exclusions
• Packaging considerations
• Intended market and compliance requirements

A clear brief gives the formulation team a better understanding of what the finished product needs to achieve.

Step 2: Ingredient Research and Selection

Ingredient selection needs to consider more than what looks good on a product concept. Ingredients need to work together within the formula and also suit the product brief, intended claims, cost expectations and manufacturing process.

At this stage, formulation teams consider:

• The ingredients the brand wants to include or avoid
• The intended product benefits and claims
• Texture and sensory preferences
• Raw material availability and cost
• How the ingredients work together in the complete formula
• Requirements that may apply in the intended market

Ingredient decisions are made as part of the complete formulation rather than one ingredient at a time, taking into account the intended product experience and future testing requirements.

Step 3: Prototype Development

Once the initial ingredient direction is defined, the formulation team begins prototype development.

The formulation team then prepares an initial lab sample for the brand to review. Depending on the product and the feedback received, the formula may be adjusted several times before it is ready to move forward, adjustments may be to:

• Texture
• Appearance
• Fragrance
• Absorption or spreadability
• Overall product feel

Prototype development is rarely a one-step process. It usually involves several iterations, each informed by technical observations and client feedback.

At Delta, prototype work is approached with the end goal in mind: a product that not only performs well in the lab, but can also move successfully through testing and into production.

Testing, Stability and Compliance

Once a formulation has been approved at lab-sample stage, testing can provide more information about how it performs over time and whether any further adjustments are needed.

A lab sample can look and feel right when it is first made, but further testing is needed to understand how the product performs over time.

Performance and Shelf-Life Testing

Testing can provide information about how a formulation performs over time and whether further development work may be required.

The testing program will depend on the product. It may include stability testing and, where relevant:

• Bacterial, yeast and mould testing
• Preservative efficacy testing

The results can help determine whether the formulation can progress or whether further development work is required.

Considering Regulatory Requirements During Development

Regulatory requirements are best considered during development rather than after the formula has already been finalised.

What needs to be considered will depend on the type of product, its ingredients, the claims being made and where the brand intends to sell it.

This is particularly important because different products can follow different regulatory pathways. A standard cosmetic product and a product making therapeutic claims, for example, may not be treated in the same way.

From Lab to Manufacturing Scale

Moving from a small lab sample to a commercial manufacturing batch is an important stage of product development.

A common challenge in product development is that a formula performs well in a small laboratory batch but behaves differently during larger-scale manufacturing. A formulation produced at lab scale may need adjustments to the manufacturing process when it is produced using larger equipment and at higher volumes.

Transitioning from R&D to Production

Once the lab sample has been approved, the manufacturing process can be developed. Where required, a pilot-scale batch can also be used before the product progresses to commercial production.

Considering manufacturing requirements during development can make the transition from lab-scale formulation to commercial production more straightforward.

This is one of the advantages of working with a formulation and manufacturing partner that can consider commercial production during development.

How Delta Supports Cosmetic Formulation

Delta works with cosmetic and skincare brands across formulation development and commercial manufacturing, helping connect the early development stages with the requirements of production.

Having formulation and manufacturing capabilities connected within the same process means production requirements can be considered earlier in development.

Delta’s formulation support can include:

• Product brief and formulation development
• Lab samples and formulation refinement
• Testing planning
• Scale-up where required
• Commercial manufacturing, filling and packing

Strong Products Begin with the Right Formulation Partner

Creating a good lab sample is only one part of developing a commercial product. The formulation also needs to progress through the appropriate testing and be successfully transferred into manufacturing.

Considering manufacturing requirements during formulation can make the transition from development to production more straightforward.

Delta works with cosmetic and skincare brands from early formulation development through to commercial manufacturing.