How we helped a superfood bar brand find a new co-packer fast and build a more resilient supply chain in the process.

The Situation

A growing superfood bar brand had been producing with a co-packer they trusted. The product was unique, built around functional ingredients that required specific equipment and processing knowledge. The brand was in active conversations with retailers and building momentum. Then, without warning, their co-packer ceased operations.

Overnight, the founder went from focusing on growth to facing a production gap. There was no backup plan, no shortlist, and retail commitments were on the line.

Why They Needed to Find a New Co-Packer Quickly

Finding a co-packer for a specialty bar product isn’t like finding one for a commodity. The formulation involved ingredients that not every facility can handle. Additionally, the production process required equipment and expertise that narrowed the field significantly. The founder was already in preliminary talks with one potential partner. However, there was no way to evaluate whether that option was the best fit or even a safe one.

Without an operations background, the founder was navigating blind. They were comparing tolling versus turnkey pricing without context and evaluating food safety certifications without knowing what to look for. Decisions were being made under pressure with no experienced operator in the room.

When your co-packer disappears, the clock starts immediately. Every week without production is a week your competitors are on the shelf and you’re not.

What We Did to Find a New Co-Packer

We moved fast. Within the first week, we pre-screened multiple co-packers with the right capabilities and certifications, including SQF, BRC, and AIB. We initiated confidential discussions under NDA. We also gathered comparative quotes across both tolling and turnkey models so the founder could make an informed decision.

We assessed each candidate on lead times, cost structure, capacity for scale, and willingness to work collaboratively with an emerging brand. Then we presented a clear evaluation report with pros, cons, and our recommendation.

Once the founder selected a partner, we provided on-site production oversight during the pilot and initial runs. Glenn was at the facility to address real-time production challenges and ensure food safety protocols were followed. He served as the bridge between the brand and the co-packer, translating the founder’s quality expectations into language the production floor understood.

The Outcome

The brand transitioned to a new co-packer without missing a retail delivery window. The new partnership was built on a proper evaluation, not a panic decision. Clear terms and mutual expectations were established from day one.

More importantly, the founder came out of the experience with tools they didn’t have before. They now had a framework for evaluating co-packers, an understanding of what a good manufacturing agreement looks like, and the confidence to manage the relationship going forward.

What Made the Difference

• Speed without panic: a structured vetting process completed in weeks, not months
• Side-by-side comparison of tolling vs. turnkey so the founder could decide with data
• On-site presence during pilot runs by someone who’s actually run a production floor
• Food safety expertise in SQF, BRC, and AIB that the founder didn’t have in-house
• A framework the founder can use to evaluate and manage co-packer relationships going forward

Lost your co-packer or worried you might?