In brief: A small Midwest protein bites brand selling through specialty retail and its own website was outgrowing its first co-packer. Rather than wait for capacity limits to cause stockouts, the brand assessed its current setup, documented its recipes and specs, and vetted and selected a new co-packer. It is now moving production through a phased transition designed to protect its retail shelf space and direct customers along the way.
Challenge
A small Midwest brand making protein bites had grown steadily through specialty retail stores and direct online sales. Its first co-packer had been the right partner at launch, but as orders grew, the fit began to change. Production runs were harder to schedule, capacity was getting tight, and the brand's plans for further retail growth were starting to outpace what its co-packer could support.
Switching co-packers carries real risk for a small food brand. A rushed or poorly planned transition can mean recipe inconsistencies, production gaps and empty shelves, putting hard-won retail relationships at stake. The brand needed a way to move to a better-fit co-packer without disrupting the customers and accounts it had already built.
Approach
Current co-packer assessment - The existing co-packer relationship was reviewed across capacity, scheduling, minimums, quality and communication, clarifying which limits were temporary and which signaled that the brand had truly outgrown the partnership.
Recipe and specification documentation - Recipes, ingredient specifications, packaging requirements and quality standards were documented in a transferable, protected format, so a new co-packer could reproduce the product consistently and the brand kept control of its know-how.
New co-packer search and vetting - Potential co-packers were evaluated against clear criteria, including capacity for future growth, minimum order sizes, food safety practices, allergen handling, location and cost, so the final choice was based on long-term fit rather than availability alone.
Transition and continuity planning - A phased transition plan maps how production shifts to the new co-packer, including trial runs, overlap with the current co-packer, and inventory buffers to keep retail and DTC orders filled during the switch. This phase is now underway.
Retail communication planning - The brand prepared how and when to update its retail accounts, so buyers see a well-managed move rather than a supply risk.
Current Status
The engagement is ongoing and the brand is now in the transition phase. With its current co-packer's limits clearly understood, its recipes and specifications documented and transferable, and a new production partner selected, the brand is moving production in planned stages designed to protect its shelf space and keep direct customers supplied throughout the move.
Outgrowing your co-packer, or worried about depending on just one? Book a 20-minute intro call, or start with the Food & Beverage Essentials, which includes a Supplier Scorecard & "Stay or Go" Diagnostic.