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Scaling Batches & Product Testing

Move from kitchen batches to repeatable production with stability testing and clean records.

21 lessons, about 5 hours

$149

lifetime access

What's inside

01From Kitchen to Batch5 lessons

1
What changes when you scale
Identify what changes between a 100 g and a 20 kg batch.
12 min
2
Equipment upgrades
Plan equipment for production. You'll cover jacketed vessels and homogenisers vs stick blenders and calibrated balances with certificates.
12 min
3
Scaling a formula safely
Scale in steps. You'll cover scale 100 g, 500 g, 2 kg, 10 kg and adjust mixing time and speed, not formula percentages.
14 min
4
Batch records
Create compliant batch records. You'll cover record: product, batch number, date, ingredient lot numbers, weights, temperatures, times, operator and keep records for the life of the product plus 3 years.
12 min
5
Workspace and workflow
Design a clean workflow. You'll cover one-direction flow: raw materials, production, filling, packing and separate clean and dirty areas.
12 min

02Quality Control5 lessons

6
Quality standards for your brand
Define what 'good' means. You'll cover set ranges: pH, viscosity, colour, scent, fill weight and create a golden reference sample.
12 min
7
pH, viscosity and appearance checks
Run quick checks on every batch. You'll cover calibrate pH meter with pH 4 and 7 buffers and measure viscosity with a simple spindle or flow cup.
12 min
8
Retention samples
Keep and use retention samples. You'll cover keep a sample from every batch for the shelf life plus 1 year and store in final packaging at room temperature.
10 min
9
Microbial risk management
Control microbial risk. You'll cover preventive controls: sanitation, water quality, preserved formulas and send finished product samples to an accredited lab on a schedule (for example, first 3 batches then quarterly).
14 min
10
Packaging and filling at scale
Fill efficiently. You'll cover compare manual, semi-automatic and automatic fillers and check fill weights every 30 minutes.
12 min

03Stability and Shelf Life5 lessons

11
Stability testing plan
Build a full stability plan. You'll cover accelerated 40 degrees C for 3 months approximates 1 year and light and freeze-thaw tests.
14 min
12
Interpreting stability results
Decide pass or fail. You'll cover signs of instability: separation, colour change, pH drift, smell change and when to reformulate.
12 min
13
Period after opening
Set a PAO. You'll cover PAO symbol: open jar with number of months (6M, 12M, 24M) and products with shelf life above 30 months do not need PAO.
10 min
14
Reformulating and versioning
Manage formula changes. You'll cover change control: reason, test, approval and update the PIF and CPSR for changes.
12 min
15
Recall readiness
Run a mock recall. You'll cover trace one batch from ingredients to customers within 4 hours and notify the competent authority and customers where required (Article 23 and General Product Safety Regulation).
12 min

04Operations at Scale6 lessons

16
Working with contract manufacturers
Evaluate contract manufacturers. You'll cover check ISO 22716 certification and site audit and agree specifications, quality agreement and ownership of formulas.
14 min
17
Costing at scale
Calculate production costs. You'll cover bulk ingredient pricing and labour and overhead.
12 min
18
Inventory and supplier management
Manage inventory. You'll cover set reorder points: lead time x daily use + safety stock and have a backup supplier for each critical ingredient.
12 min
19
Customer feedback and complaints
Handle complaints. You'll cover log every complaint with batch number and investigate within 5 working days.
12 min
20
Certification project and final review
Complete your certification project. You'll cover choose one product from your starter line and submit: formula in percentages, PIF contents list, label draft, stability plan, claims review, batch record.
25 min
21
Certification exam
Pass a 10-question exam (80% to pass, 3 attempts) to complete your certification.
20 min