Learn before you commit to scale.
A pilot run is where a formula meets a real process. It exists to expose problems while they are still cheap to fix — not to be discount manufacturing.
100–500
Typical units per run
Development scale
Why pilot scale
Small enough to learn from. Large enough to be real.
A run of this size tells you what a bench sample cannot: whether the process repeats, whether the packaging behaves, what the unit actually costs, and how the product holds up in the hands of real users — all before you carry the risk of a first full inventory.
Process
Repeatability beyond the bench
Presentation
Fill, closure and finished-unit consistency
Stability
Real units in real packaging
Feedback
Units for controlled market review
Cost
Actual material and process economics
Scale
A documented basis for larger production
Run sheet
Plan. Execute. Observe. Assess.
- 01
Pilot plan
Batch size, process steps, materials and checks defined.
- 02
Batch execution
A development-scale run, typically 100–500 units.
- 03
Observation
Process behaviour and finished-unit characteristics recorded.
- 04
Scale assessment
Changes required before larger production are stated.
Position
Development-scale, not low-MOQ manufacturing.
Manufacturing is a secondary function here; it supports the development work rather than the other way around. Pilot batches are scoped around technical readiness, and larger commercial production is planned only once the process has been established.
Start with the project as it is today
Is the formula ready for a pilot run?
Tell us where the project stands today. Every brief is reviewed for technical fit, development readiness and current laboratory capacity — you do not need all the technical answers first.
Why pilot runs are 100–500 units →Six short steps. No account, no pricing gate.
Or contact the laboratory directly