Reformulating an Existing Supplement: When and How to Do It Right
Sometimes, a supplement that looked good on paper simply doesn’t work in the real world. Maybe it’s clumping in the capsule, oxidizing on the shelf, or causing user complaints about taste and texture. In other cases, a brand might switch contract manufacturers and find out that their original formula isn’t compatible with the new machinery.
At BF‑EssE, we help clients diagnose, correct, and optimize underperforming or unstable formulations — turning problematic products into stable, manufacturable, and scalable solutions.
At BF‑EssE, we help clients diagnose, correct, and optimize underperforming or unstable formulations — turning problematic products into stable, manufacturable, and scalable solutions.
Common Problems with Existing Formulas
Before we touch a formula, we always ask:
“Why is this formula being reformulated?”
In our experience, these are the most common reasons:
“Why is this formula being reformulated?”
In our experience, these are the most common reasons:
1. Poor Powder Flowability & Non-Granulated Mixes
One of the top reasons for reformulation is bad flow behavior — especially in capsules, sachets, or filling equipment.
- Non-granulated powders can stick, bridge, or clog dosing equipment.
- Flow issues lead to inconsistent capsule fill weights or under/overfilled sachets.
- Excipients may be missing or incorrectly used (e.g. no glidants or binders).
2. Changing Manufacturers = Changing Machines
Every manufacturer has its own machines, setups, and internal tricks.
A formula that runs perfectly at one site may jam, underdose, or misbehave at another.
For example:
A formula that runs perfectly at one site may jam, underdose, or misbehave at another.
For example:
- Tablet presses may differ in compression force tolerance.
- Capsule fillers may use different feeding systems (auger, vacuum, paddle).
- Sachet fillers may demand specific bulk densities and flow properties.
- Herbal extract mixes and colorants
- Sachets with different colours and flavours
- Herbal etxtracts and capsules from them
3. From Stamped Pin to Auger Filler (or Vice Versa)
Transitioning from one type of filling system to another is a formulation-critical change.
Transitioning from one type of filling system to another is a formulation-critical change.
- Stamped pin systems (often used for capsule or tablet filling) require a compressible, cohesive mix.
- Auger fillers (used for powders or sachets) rely on free-flowing material that doesn’t clog or bridge.
- Flow enhancers (e.g. silicon dioxide, magnesium stearate)
- Particle morphology
- Mixing time and excipient choice
4. Stability Problems: Oxidation, Heat, and "Burn Points"
Some blends degrade during storage or even during production — especially botanical extracts, oils, or unstable actives.
Some blends degrade during storage or even during production — especially botanical extracts, oils, or unstable actives.
- Oxygen-sensitive ingredients (like some vitamins, amino acids, or plant actives) can oxidize inside capsules.
- Some blends generate heat when compressed or agitated — reaching so-called "burn points" where actives break down.
- We’ve seen formulas literally change smell or color within weeks of packaging.
- Oxygen exposure during mixing
- Encapsulation timing
- Addition of antioxidants or microencapsulation
- to protect your formula’s active content over time.
5. Hydrophilic Mixes Ruining Capsule Shells
Some ingredient blends are highly hydrophilic — they absorb moisture from the gelatin capsule shell. The result?
Some ingredient blends are highly hydrophilic — they absorb moisture from the gelatin capsule shell. The result?
- Capsules turn fragile and brittle
- When removed from blisters, they crack or disintegrate
- Consumer experience suffers (and complaints increase)
- Reducing moisture activity of the mix
- Using desiccant packaging or alternative shells
- Adjusting excipient blends to “hold” less moisture over time
6. Color Instability in Pigmented or Botanical Mixes
Natural or synthetic colors can fade or change depending on:
- pH
- Oxidation
- Temperature
- Light exposure
- Pink today and brown in 3 months
- Or green in the factory and grey at the store
7. Loss of Taste, Smell, or Aroma Over Time
Some formulations lose their signature flavor, aroma, or sensory appeal after a few weeks — especially in sachets, syrups, or open-tablet blisters.
Why this happens:
Why this happens:
- Volatile aroma compounds degrade
- pH or oxidation alters flavor profile
- Packaging does not protect organoleptics
- Adjusting pH or adding stabilizers
- Selecting better flavor systems (e.g. encapsulated flavors)
- Improving barrier packaging
When to Reformulate: Signs It's Time
You may need to reformulate when:
You may need to reformulate when:
- You switch contract manufacturers
- You get complaints from customers or distributors
- The product fails internal QC (flow, color, stability, sensory)
- You want to scale to larger batches, new formats, or tougher climates
- You plan to register in new regions with different regulations
How BF‑EssE Handles Reformulation
- Full technical assessment of the current formula
- Material behavior profiling (flow, stability, sensory)
- Machine-matching to BF‑Esse equipment
- Optimized prototype with new excipients or process
- Validation batch and QC testing
- Optional: Accelerated stability testing
Reformulating isn’t admitting failure — it’s an opportunity to make your product better, more stable, and more competitive. Whether you’re switching manufacturers, upgrading stability, or solving a long-standing technical issue, our team can help you do it right.
Reach out to BF‑EssE
to discuss your reformulation needs.
Reach out to BF‑EssE
to discuss your reformulation needs.
Explore BF-EssE's other services
Frequently Asked Questions
Common reasons include poor flowability, ingredient incompatibility with machines, stability issues (oxidation, moisture, etc.), or a manufacturer change requiring process adjustments.
Color fading, odor changes, ingredient degradation, fragile capsules, or clumping powders can all signal stability problems. These issues often show up during storage or transport.
Yes. Each contract manufacturer uses different machines, tooling, and processes. A formula that works well on one production line may fail on another without proper adjustment.
Auger fillers are better for free-flowing powders (like sachets), while stamped pin systems need compressible, cohesive blends (like capsules or tablets). Each system requires specific flow behavior.
This usually comes from moisture migration. We reformulate the powder blend to reduce hygroscopicity, adjust the capsule shell, and test different blister barrier options.
Absolutely. Our goal is to improve manufacturability and stability while preserving the supplement’s intended function, taste, and marketing claims.