The Custom Formulation (OEM) Process: Step-by-Step
Creating a custom formula from scratch is a journey of science and art. Unlike Private Label (which takes 3 weeks), Custom OEM projects typically require 3-6 months to ensure stability and safety.
Here is the professional workflow at Aurora Global Brands:
Phase 1: Discovery & Briefing
Before we enter the lab, we must define the target.
1. The “Benchmark” Sample (Crucial)
- We need a physical reference. The fastest way to get exactly what you want is to send us a “Benchmark Sample” (e.g., a bottle of the Estée Lauder serum or Fenty gloss you want to replicate or improve).
- Why? Descriptions like “hydrating” or “silky” are subjective. A physical sample allows our chemists to analyze the exact viscosity, pH, and texture in the lab.
- The Brief: You tell us: “I want the texture of Product A, but with the active ingredients of Product B, and the scent of Product C.”
2. Project Quote & R&D Fee
- MOQ Check: We confirm you can meet the 100kg minimum (approx. 3,000 – 5,000 units depending on fill weight).
- R&D Deposit: A formulation fee (typically $200 – $500, depending on complexity) is required to start the project. This covers the chemist’s time and raw materials. This fee is often credited back if you place a bulk order.
Phase 2: R&D & Prototyping
The chemistry begins.
3. First Prototype (14-21 Days)
- Our R&D team reverse-engineers your benchmark or builds your formula from scratch.
- We source specific active ingredients (e.g., Peptides, Hyaluronic Acid) from our global suppliers.
- Result: You receive Lab Sample V1.
4. Feedback & Revision
- You test V1. Is it too sticky? Is the scent too strong?
- You give detailed feedback.
- Revision: Our chemists adjust the formula. (We typically offer 2-3 rounds of free revisions).
- Final Approval: You sign off on the formula: “This is the one.”
Phase 3: Testing & Compliance
This is the most critical phase for safety. We cannot rush science.
5. Stability & Compatibility Testing (4-8 Weeks)
- Once the formula is approved, we MUST test it to ensure it doesn’t separate, change color, or grow bacteria over time.
- Oven Test: We put the product in 45°C ovens to simulate 3 years of aging.
- Compatibility Test: We put the formula inside your chosen packaging (bottle/pump) to ensure they don’t react (e.g., the formula doesn’t melt the plastic pump).
- Note: Skipping this step risks your product leaking or spoiling on the shelf.
Phase 4: Mass Production
Scaling up from beaker to manufacturing tank.
6. Production & Filling (30-45 Days)
- Raw Material Procurement: We buy the ingredients in bulk (drums/kilos).
- Bulk Manufacturing: The formula is made in large stainless steel emulsification tanks.
- Microbiological Check: We test the bulk for bacteria/mold before filling.
- Filling & Packing: The bulk is filled into your bottles, capped, labeled, and boxed.
💡 Summary Timeline
❓ FAQ: Custom Formulation
Q: Do I own the formula? A: Yes. Unlike Private Label (where you rent our formula), with OEM, if you pay the full R&D development fees, you own the Intellectual Property (IP) of that specific formula. We will not sell your unique formula to another client.
Q: Can I bring my own raw materials? A: Generally, no. For quality control (GMP) reasons, we must source ingredients through our verified supply chain. However, if you have a proprietary patented extract, please discuss it with our project manager.
Q: Why is the MOQ 100kg? A: Industrial emulsification machines have a minimum capacity. We cannot mix just 5kg effectively in a 500kg tank—the blades wouldn’t even touch the liquid. 100kg is the smallest efficient run for professional equipment.
