Challenge
The customer wanted to add a focus-and-stamina capsule line to their EU functional-mushroom range. Two non-negotiables: (1) every batch must clear the same retailer-audit panel as their existing premium SKUs (heavy metals to USP <232>, glyphosate and 64-pesticide multi-residue under EU MRLs, no irradiation, no maltodextrin carriers); (2) two actives — cordyceps and lion's mane — must be sourced from the same supplier to simplify QA and reduce shipping consolidation.
Approach
We started with a paid working sample of cordyceps mycelium extract at our standard 30% beta-glucan grade plus a lion's mane fruit-body extract at 25%. Their formulation team ran 4 weeks of in-house stability and capsule fill testing. Once spec was locked, we agreed on per-batch retailer-audit documentation (COA + pesticide multi-residue + heavy metals every batch, not on rotation) and a 21-day standard lead time.
Outcome
First two production batches cleared the retailer audit on first submission. Beta-glucan content held at 31.2% and 30.8% (vs spec 30%). The customer ramped to 60 kg combined monthly volume in their second month and we reduced lead time to 18 days after Q4 capacity expansion.
Formulation notes
Capsule fill: 500 mg cordyceps + 250 mg lion's mane per Size 0 veg cap, no excipients. The customer chose a non-coated DRcap (Capsugel) for stomach-acid resistance — common for fungal-extract products since stomach acid can degrade some beta-glucan structure.