Custom Formulation Powered by Science
Science-Driven Custom Supplement Formulation for High-Performance Brands
At AirVigor, custom formulation isn’t contract manufacturing — it is precision nutrition engineering. With 25+ researchers, 20,000+ validated formula models, a full in-house lab, and GMP-certified production, we design high-performance formulas trusted by professional athletes, fitness creators, and global wellness brands.
From electrolytes to creatine blends, hydration powders, recovery complexes, functional minerals, and multi-ingredient performance systems, every formulation is built on real science—not marketing claims.
What Makes AirVigor a World-Class Formulation Partner
The advanced science, global certifications, and manufacturing depth behind your product success.
AirVigor is not a typical supplement manufacturer — we operate as a sports nutrition R&D institution with complete formula engineering, lab validation, and regulatory adaptation across 120+ global markets.
We offer:
- Clinical-dose ingredient design, not concept ingredients
- Electrolyte-to-metabolism formula modeling for athletic needs
- In-house flavor science, solubility optimization & powder-flow engineering
- Global compliance support (FDA, HACCP, ISO22000, Halal, Kosher)
- Packaging R&D, sealing tests, moisture-resistance modeling
- GMP manufacturing, with batch traceability & stability testing
Our Scientific Framework for Custom Formulation
A Scientific System Built for Performance-Based Nutrition
Every AirVigor formula begins in our biochemistry and sports nutrition laboratory. We evaluate formulas based on:
| Scientific Principle | What We Test | Why It Matters |
|---|---|---|
| Absorption Pathways | Osmolality, ionic transport | Ensures real hydration & performance output |
| Sweat-Loss Ratios | Sodium–Potassium–Magnesium balance | Prevents cramps, dizziness, mid-workout crashes |
| Energy Metabolism | ATP regeneration, creatine kinetics | Supports lifters, HIIT athletes & endurance users |
| Solubility Optimization | Dissolution rate, powder flow | Guarantees smooth mouthfeel & fast mixing |
| Stability & Shelf Life | Moisture, temperature, pH testing | Protects product quality during shipping & storage |
| Flavor & Sensory Science | Bitterness masking, natural profiles | Improves daily compliance & repurchase rate |
This is how we guarantee science-first supplements that perform in real athletic environments — not just on paper.
Formulation Categories We Specialize In
High-performance formulas for hydration, strength, recovery, wellness, and metabolic support.
AirVigor supports brand partners with formulation across 13+ advanced supplement categories, all validated for performance, safety, global compliance, and scalability:
Hydration & Electrolytes
- Zero-sugar electrolyte powders
- Sodium/potassium/magnesium performance blends
- Athletic hydration systems for runners, cyclists, CrossFit, HIIT
Strength & Muscle Performance
- Micronized creatine monohydrate
- Creatine complexes (creatine + electrolytes, creatine + carbs)
- ATP & power-output supporting blends
Recovery & Wellness
- Magnesium recovery formulas
- BCAA + electrolyte hybrids
- Collagen hydration formulas
- Mineral balance complexes
Daily Health & Lifestyle
- Multimineral daily hydration
- Focus blends for high-performance professionals
- Balanced electrolyte options for travel, heat exposure, and jet lag
Every formula is designed for real-world usage, not theoretical claims.
Premium Ingredient Sourcing Backed by Global Certifications
Traceable, pure, clinically aligned ingredients — validated by world-class safety systems.
Our raw materials are sourced from audited global suppliers and verified through:
- COA ingredient verification
- Purity & identity testing
- Heavy metal and microbial limits
- pH, solubility, moisture and particle-size analysis
- Halal, Kosher, Organic audits when needed
- FDA-compliant labeling standards
- EU & Japan compliance adaptations
We ensure every formula meets international supplement regulations, enabling seamless entry into US, EU, Canada, Japan, Australia, and Southeast Asia markets.
From Concept to Formula
Proven 7-Step Formula Development Workflow
Every custom formula follows AirVigor’s standardized R&D and manufacturing pipeline, ensuring precision, repeatability, safety, and market-ready quality. Our workflow eliminates ambiguity and accelerates your path from concept → prototype → retail launch.
1. Discovery & Requirement Mapping
We analyze your target users, athletic intensity, distribution markets, budget, flavor direction, and compliance requirements.
2. Ingredient & Scientific Framework Design
Our researchers build a formulation matrix based on:
- sweat-loss ratios
- metabolic pathways
- absorption kinetics
- clinical dosage references
- sensory & solubility constraints
3. Prototype & Lab Testing
Formulas undergo:
- solubility optimization
- stability testing
- osmolality calibration
- flavor adjustment cycles
4. Sensory & Performance Validation
We test in real sport environments—HIIT, running, cycling, resistance training—to optimize performance response.
5. Regulatory & Label Compliance
Formulas are adapted to:
- FDA guidelines
- EU EFSA claims
- Japan FOSHU rules
- GCC, SEA, LATAM regulations
6. Pilot Batch Production
Small-batch production validates:
- powder density
- flow behavior
- mixing properties
- packaging interaction
7. Mass Production & Global Readiness
Final formulas enter GMP production with batch traceability and multi-country labeling.
Packaging Engineering & Stability Testing
Engineered to maintain purity, solubility, and stability across global climates.
AirVigor designs packaging as part of the scientific formula system, not as an afterthought. Our packaging lab evaluates:
- Moisture barrier performance
- Oxygen transmission rate (OTR)
- Heat-seal integrity
- Long-haul shipping durability
- Flavor retention & stability
- Powder flow behavior under humidity
- Light-sensitivity & nutrient degradation
Every packaging design undergoes sealing, drop, vibration, thermal, and humidity stress testing.
We design different structures for different use cases:
| Use Case | Package Type | Benefit |
|---|---|---|
| Training & outdoor | Stick packs | Quick rip-open, sweat-proof, portable |
| Home & daily | Jars | Frequent-use friendly, airtight |
| Refill packs | Stand-up pouches | Cost-effective, eco-friendly |
| Teams & gyms | Bulk bags | High-volume use, reduced cost |
Real Success Stories From Our Global Formulation Partners
How AirVigor’s science-led system accelerated brand performance worldwide.
We support more than 210,000+ consumer and brand-side users across 120+ countries. Here are examples of partnerships that scaled through our custom formulation program:
Case Study 1 — U.S. Hydration Startup
Goal: Launch a clean zero-sugar electrolyte powder for runners. AirVigor Solution:
- Clinical-dose electrolyte ratio
- Fast-solubility design
- Citrus flavor engineering
Outcome: Rated 4.7 on Amazon, expanded into 5 SKUs within 12 months.
Case Study 2 — EU Cycling Nutrition Brand
Goal: Prevent mid-ride performance crashes and muscle cramps. Solution:
- Sodium-potassium-magnesium sweat-loss modeling
- EU regulatory label adaptation
Outcome: Used by cycling clubs across Germany & the Netherlands.
Case Study 3 — APAC Corporate Wellness Line
Goal: Daily hydration for office professionals. Solution:
- Low-osmolality hydration formula
- Portable stick packaging Outcome: Became a top-selling corporate wellness supplement.
World-Class Manufacturing for High-Performance Formulas
A vertically integrated facility ensuring purity, precision, and scalability.
AirVigor operates a fully integrated manufacturing ecosystem that includes:
GMP-Certified Nutrition Factory
- High-shear mixers
- Powder blenders
- Automated filling + sealing machines
- Batch-coded packaging system
Food-Grade Packaging Factory
Providing:
- Stick-pack film
- Jar & pouch structures
- Printed labels
- Batch-tracking ink systems
In-House Printing Facility
Ensures:
- Global label compliance
- Multi-language packaging
- Ultra-low color variance
- Sweat-resistant finishes
Our 15000+ sqm facility includes:
- 100,000-grade clean rooms
- 25+ QA/QC inspectors
- Microbial / heavy metal / purity testing
- COA, MSDS, Halal, Kosher, Organic, FSSC documentation
This allows us to deliver consistent, stable, globally compliant formulas.
Custom Flavor Engineering Lab
Scientifically balanced flavor systems for athletes and lifestyle users.
AirVigor develops high-performance flavors that support hydration and long-term consistency. Our flavor engineering process optimizes:
- Sweetness curve balance
- Acid profile & mouthfeel
- Natural fruit notes
- Bitterness masking
- Electrolyte taste compensation
- Low-osmolality flavor stability
Flavor categories include:
- Citrus (lemon, lime, orange)
- Berry (blueberry, strawberry, raspberry)
- Tropical (mango, pineapple, lychee)
- Functional neutrals (unflavored, light mineral taste)
We analyze sensory fatigue, exercise tolerance, and psychological acceptance to ensure flavors work during real athletic performance — not just in a lab.
Frequently Asked Questions About Custom Formulation
Clear answers for new brands, growing companies, and enterprise clients.
1. How long does custom formulation take?
Usually 7–10 days depending on complexity, ingredient sourcing, and flavor cycles.
2. What is the MOQ for custom formulas?
Standard MOQ: 500 units, with flexibility for pilot batches.
3. Do you provide samples before production?
Yes — 3 stick packs for powders, 1–2 bottles for capsules/gummies.
4. Can AirVigor adapt formulas for the U.S., EU, Japan, or Middle East?
Yes — we specialize in global regulatory adaptation.
5. Can we customize electrolytes, creatine, collagen, or multi-complex formulas?
Yes — more than 13 validated categories supported.
6. Do you support Amazon-ready packaging?
Absolutely — including barcodes, FNSKU, batch codes, shelf-life validation.
7. Can we develop multiple flavors?
Yes — flavor flights available (3–8 candidates per development cycle).
8. Are your ingredients traceable?
100% traceable with COA and QA documentation.
9. Do you offer private label and ODM services?
Yes — from formula → design → packaging → production → logistics.
10. Do you support global shipping and multi-country warehousing?
Yes — with U.S., EU, JP, and AU distribution networks.
Ready to Build a High-Performance Supplement With AirVigor?
Let our scientists, engineers, and manufacturing teams bring your formula to life.
Whether you’re launching your first hydration product or scaling an established performance brand, AirVigor provides the scientific foundation, manufacturing power, and global compliance to make your formula world-class.
From concept → R&D → packaging → GMP mass production — we take care of everything with precision, transparency, and athlete-driven validation.
Your next best-selling formula begins here.