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Beverage Prototyping

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Beverage Prototyping

Prototyping is the process of creating small batches of your beverage to test flavor, function, appearance, and stability before full-scale production. It’s the bridge between formulation and pilot production.

Goals of Prototyping

  • Validate your formulation in real conditions (bottle/can, shelf, temperature)

  • Refine taste, sweetness, texture, and aroma

  • Test consumer reactions

  • Identify separation, sedimentation, or off-flavor issues

  • Prepare for scale-up by stress-testing the recipe

Key Elements of Beverage Prototyping

Batch Size

Typically: 1 to 5 liters (lab-scale), For advanced validation: 10–20L for broader sensory testing or shelf-life studies, Made in sanitized lab or test kitchen settings.

Small-Scale Equipment Used

Precision scales: accurate to milligrams, Magnetic stirrers / blenders: for proper mixing/emulsifying, Hot plates or water baths: for simulating pasteurization, CO₂ infusers: for carbonation testing, Filling equipment: manual fillers for bottles or cans, pH meters & refractometers: for acidity and Brix (sweetness) levels.

Sample Packaging

Glass bottles, PET bottles, or aluminum cans, Sealed using heat-sealers or crowning machines,
Labelled with batch info, pH, Brix, and ingredients.

Sensory Evaluation

Flavor (balance of sweet, bitter, tart), Aroma, Mouthfeel (thickness, carbonation, creaminess),
Aftertaste, Conducted with internal team or external panel.

Stability Testing

Sedimentation, Separation (especially with oil- or juice-based drinks), Cloudiness or color change,
Carbonation retention.

pH and Brix Monitoring

Target beverage pH (e.g., 2.8–4.0 for shelf-stability), Brix should match expected sweetness (typically 4–14°Bx).

Emulsion or Solubility Testing

Caffeine or adaptogens, Flavor oils (e.g., citrus oil), Plant extracts.

Packaging Interaction

Light and oxygen sensitivity, CO₂ loss (for carbonated beverages), Flavor leaching or migration.

Consumer Feedback

Sweetness level, Flavor identity and likability, Aftertaste, Visual appeal (color, clarity, packaging)

Example Prototype Process (Energy Drink Scenario)

  • Mix dry ingredients (caffeine, L-theanine, vitamins, sweeteners)

  • Add base water and functional extracts (berry juice, adaptogen)

  • Stir and emulsify using high-speed stirrer (for solubility)

  • Measure pH → Adjust with citric acid to reach ~3.2

  • Flavor check → Adjust stevia/monk fruit ratio

  • Carbonate sample and bottle in glass

  • Observe shelf behavior for 2 weeks

  • Conduct sensory panel

  • Refine formula based on feedback

FEEL FREE TO TALK TO US ABOUT YOUR BEVERAGE PROJECT!
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