Launching a sports supplement — whether it’s a protein blend, pre-workout, or hydration powder — can feel overwhelming. You’ve got a vision, maybe even some early product samples, but turning that into a retail-ready, compliant, and scalable product requires a few critical steps. At Mansfields, we work with a range of growing brands, and this is the exact path we help them navigate — from idea to shelf.
Here’s how to do it.
✅ Step 1: Define Your Product & Market
Start with the “what” and the “who.”
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What is your product: protein powder? Pre-workout? Electrolyte blend?
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Who is it for: elite athletes, weekend warriors, vegans, women’s fitness, endurance runners?
Tip: The more specific your market, the easier it is to stand out. Niche wins.
⚗️ Step 2: Formulation & Ingredient Selection
Now you define the functional side of the product. This includes:
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Core ingredients (e.g. whey isolate, creatine, BCAAs, caffeine, electrolytes, etc.)
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Additives & sweeteners (natural vs. artificial)
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Compliance needs (TGA, vegan, gluten-free, allergen-free)
If you have a formula already, great — we can help refine it for scale. If not, we offer formulation support to help you hit the right balance of efficacy, taste, and manufacturability.
Step 3: Packaging Decisions
Packaging affects everything — your cost per unit, shelf appeal, and sustainability claims.
Choose between:
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Jars/tubs (great for value-based fitness consumers)
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Sachets (perfect for samples or travel use)
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Biodegradable packaging (if you want to stand out with an eco-angle)
Make sure you also consider:
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Label design
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Compliance (ingredient listings, warnings, nutrition info)
Step 4: Sampling & Testing
Before full production, you’ll want to test:
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Taste & texture
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Solubility
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Shelf life & packaging compatibility
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Consumer feedback from test groups
This is also where we can run pilot batches and make any final tweaks.
Step 5: Manufacturing & Minimum Order Quantities (MOQs)
This is where the rubber meets the road.
At Mansfields, we specialise in high-volume, dry powder production. For a full commercial run to be viable, you’ll need to hit:
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~10,000 units per SKU
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or a total run of 60,000+ units across SKUs
This ensures cost-efficiency and proper production sequencing.
Step 6: Logistics, Labelling & Delivery
Once your products are packed and sealed, they need to be:
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Labelled to spec
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Palletised and shipped to warehouses or 3PLs
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Supported with batch testing results (especially if exporting or going into retail)
We help with all of this — and can even provide storage and freight solutions depending on your scale.
Step 7: You’re on the Shelf (or in the Cart)
Whether you’re selling DTC, in supplement stores, or through distributors — this is where your marketing kicks in. But the heavy lifting on the product side is done. You now have:
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A reliable manufacturing partner
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A formula you can scale
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Packaging that fits your market
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Systems in place to reorder, expand, and grow
Final Word
Getting from idea to shelf isn’t easy — but it’s absolutely doable with the right partner. If you’re ready to scale or start fresh with a high-quality manufacturing team, reach out to Mansfields. We specialise in dry powder manufacturing for sports nutrition brands looking to grow.
Want help bringing your sports supplement idea to life?
Get in touch today — and let’s build something that performs as hard as your customers do.
For more information email us here: sales@mansfields.com.au
or
Call (03) 9701 8711