From Spark to Shelf: The Real Roadmap to Launching a Food or Beverage Product
Innovative ideas are common. Successfully launched products are not.
Bringing a food or beverage concept to market involves far more than creativity. It requires technical feasibility, processing know-how, commercialization strategy, and deep cross-functional expertise. Most concepts for food tech startups or beverage companies never make it past the pilot phase—not because they’re bad ideas, but because they aren’t built to scale.
At The National Food Lab, we leverage our experience working with the top food and beverage companies to guide brands from concept to commercialization. As part of the Eurofins network, we combine scientific depth with real-world product development experience to help our clients launch products that perform—on shelf and in market.
This roadmap outlines the seven key stages required to take a product from initial idea to successful commercial launch—along with the risks, requirements, and technical checkpoints involved at each step.
STAGE 1: SPARK — DEFINING A VIABLE CONCEPT
Every successful product starts with a clear, focused vision. But even the most compelling ideas must be grounded in technical and operational reality.
At this stage, we help you:
- Define functional, nutritional, and sensory targets
- Identify early feasibility risks
- Assess ingredient compatibility, processing needs, and potential regulatory considerations
Early-stage feasibility checks reduce rework, shorten timelines, and save money. We help you move forward with confidence—based on data, not guesswork.
STAGE 2: PROTOCEPTS — TURNING IDEAS INTO TESTABLE FORMULAS
A protocept is more than just a benchtop sample—it’s a formulation built for learning. We use protocepts to test key assumptions about ingredient behavior, sensory characteristics, and process fit.
We support this phase with:
- Iterative formulation development
- Ingredient functionality screening
- Initial processing and stability assessments
- Flexibility to explore clean label, high protein, allergen-free, and other product claims
Protocepts vs. Prototypes:
A prototype is typically designed for presentation. A protocept is created for validation. TNFL starts with protocepts to understand what’s feasible—technically, operationally, and commercially—before finalizing a formulation.
Need consumer feedback? We can connect with Eurofins SAM Sensory and Consumer Research to support testing at this stage.
STAGE 3: FEASIBILITY & RISK ASSESSMENT
Once an initial direction is established, it’s critical to identify how the formulation will behave under commercial conditions. This is where we assess the “what ifs” that could impact your product during manufacturing or on shelf.
We evaluate:
- Thermal and mechanical stress impact
- Ingredient interactions and stability
- Risk of separation, gelling, or phase changes
- Early shelf-life performance
- Compatibility with target packaging types
This is where most early-stage concepts break down. We help clients address potential issues before scale-up—minimizing downstream delays and formulation rework.
STAGE 4: SCALE-UP & PILOT TRIALS
The transition from lab to production is one of the most technically challenging phases of product development. What works on the bench may not translate directly to pilot or commercial equipment.
We guide clients through:
- Pilot trials that replicate commercial conditions
- Optimization of shear, temperature, and hold times
- Adjustments to processing order and batch parameters
- Sensory and physical evaluations post-scale
Need a Process Authority Letter?
TNFL is a certified Process Authority and can develop and validate the thermal process for shelf-stable and acidified products. We provide the documentation required by co-manufacturers and regulatory bodies to move forward confidently.
Validated prototypes can be created at this stage to reflect the final product. These samples are useful for internal approvals, early-stage sales conversations, and investor engagement.
STAGE 5: CO-MANUFACTURING TRANSFER
Securing a co-manufacturer is a major milestone—but transferring your formulation successfully requires precision. A strong formula on paper must be matched with a process that works for the facility’s equipment and constraints.
TNFL helps by:
- Preparing process-ready documentation and SOPs
- Supporting initial production runs
- Troubleshooting in real time
- Adjusting formulation details for co-man compatibility
We act as a technical liaison between you and your co-manufacturer—ensuring the product is reproducible at scale, not just in the lab.
We also provide early guidance on sourcing considerations, MOQ challenges, and ingredient availability to avoid scale-up surprises.
STAGE 6: STABILITY, SHELF LIFE & PACKAGING
A technically sound product must also remain stable through distribution and shelf life. We evaluate real-world performance through integrated testing protocols.
Our stability programs include:
- Real-time and accelerated shelf-life studies
- Water activity, oxidation, pH, and microbial testing
- Packaging interaction assessments (glass, PET, pouches, etc.)
- Sensory degradation monitoring
Shelf-life failure is one of the most costly mistakes in product launches. TNFL’s in-house testing capabilities allow us to identify risks early and keep your launch timeline on track.
STAGE 7: POST-LAUNCH OPTIMIZATION
Product development doesn’t stop at launch. As your business grows, your needs will evolve—from cost management to flavor extensions to troubleshooting production challenges.
We support ongoing product success through:
- COGs optimization
- Ingredient substitutions
- Production efficiency improvements
- Support for new SKUs, formats, and packaging lines
We aim to be a long-term partner—not just a development vendor. Whether you’re fine-tuning costs or preparing for your next release, we stay involved to help you grow with agility.
WHY THE NATIONAL FOOD LAB?
What sets TNFL apart from other development firms is the breadth of our services, our technical depth, and our integration with Eurofins' global science network. We provide:
- Science-first formulation and scale-up strategy
- Pilot plant and thermal processing expertise
- Process Authority validation for regulatory compliance
- Integrated stability and packaging testing
- Support across sourcing, manufacturing transfer, and post-launch optimization
We support clients ranging from funded startups to Fortune 500s—and meet you wherever you are in your journey.
LET’S WORK TOGETHER
Have a new idea? Running into production challenges? Planning your next launch?
