How Are Pre-Workout Supplements Made? A Behind-the-Scenes Look at the Manufacturing Process

By Rick
Handel
06/16/2025

Build a pre-workout your customers will rave about. Start with a deeper understanding of how it’s made and get insider tips on formulation, flavor, and ingredient quality in this article!

If you’ve ever wondered how pre-workout supplements are made, this article offers a comprehensive, expert-driven look into the process behind one of the most popular supplement categories in the nutraceutical industry.

We’ll cover what pre-workout supplements are, the benefits of pre-workout, why they’re in high demand, and most importantly, the critical steps involved in manufacturing them.

Whether you’re a brand owner exploring product development or simply curious about what goes into making a high-quality pre-workout formula, this guide walks you through every stage of production.

What is Pre-Workout?

Pre-workout products are dietary supplements that may include a broad range of nutraceuticals such as energy-boosting ingredients, stimulants, and performance-enhancing nutraceuticals designed to help replenish energy reserves and enhance workout intensity and quality.

Most pre-workouts are manufactured in powdered form, so the end user (i.e., your customer) can easily mix them with water or their liquid of choice. Pre-workout supplements are generally taken before, and in some cases during, a workout to improve performance outcomes, offering greater benefits than hydration with water alone.

What Does Pre-Workout Do?

The benefits of pre-workout supplements extend well beyond a simple energy boost. When properly formulated by a qualified sports nutrition supplement manufacturer, these products can enhance multiple aspects of physical and cognitive performance. Key benefits include increased stamina, improved focus, greater strength output, and faster recovery, making them a valuable tool for amateur and professional athletes, as well as “Weekend Warriors.”

Ingredient profiles often include compounds that support blood flow, oxygen delivery, and nutrient transport to working muscles, helping to improve overall workout efficiency. This can translate to more productive training sessions, improved muscle endurance, and long-term performance gains.

Whether the goal is strength building, weight management, or endurance, pre-workout supplements are designed to support a wide range of fitness objectives, making them one of the most versatile and widely adopted product classes in the nutraceutical space.

Why Should Brands Consider Manufacturing Pre-Workout Supplements?

Pre-workout supplements represent a high-growth opportunity for supplement brands seeking to start or expand their product line. Market trends show that increasing demand is being driven by growing consumer interest in fitness, performance enhancement, and health optimization, especially with the influence of wearable technology. For brand owners, the key is not only to capitalize on this demand but also to differentiate through formulation, positioning, and delivery formats.

Growing Market Demand

The global size of the pre-workout supplements market is expected to reach $20.98 billion in 2025 (up from $19.58 billion in 2024) and is projected to grow to $27.97 billion by 2030, with a compounded annual growth rate (CAGR) of 5.9%.¹

This growth is being fueled by increasing consumer awareness of the performance benefits of pre-workouts, such as enhanced energy, focus, and endurance, as well as the rise of fitness centers and home-based workouts. These trends make pre-workout a compelling category for both emerging and established nutraceutical brands.

The Use of Wearable Devices

In 2024, 38% of consumers reported using wearable fitness devices (e.g., Oura Ring, Apple Watch, Fitbit), and 46% of them used these tools to track exercise performance. Notably, 50% of wearable users said the data influenced their supplement purchasing decisions. With fitness and energy supplements holding the largest market share at 18.2%, the opportunity for pre-workout products to align with personalized, data-driven fitness goals has never been greater.²

Customization & Brand Differentiation

To succeed in the competitive pre-workout supplement market, brands must establish a strong unique selling proposition (USP) that sets their product apart. Customization, through formulation, ingredients, delivery format, and flavor, can be a powerful differentiator.

Targeted formulations are one way to create value and align with consumer goals. For example, your pre-workout could be formulated specifically for:

Weight management
Muscle repair and hypertrophy (increased muscle size)
Mental focus and cognitive performance

Ingredient transparency and lifestyle alignment are also key drivers of consumer choice. Consider incorporating attributes such as:

Sustainable or ethically sourced ingredients
Vegan-friendly formulations
Non-GMO and organic certifications
Sugar-free or keto-friendly formulations

Innovative delivery formats, such as effervescent tablets, can further differentiate your product. These formats offer convenience and a unique user experience, especially when compared to traditional powders. Flavor innovation is another opportunity to stand out in a crowded space and build lasting customer appeal.

Ultimately, a well-defined USP not only attracts new customers but also fosters brand loyalty and repeat purchase behavior.

The Pre-Workout Manufacturing Process

Creating a high-quality pre-workout supplement involves multiple steps, from scientific formulation to precision blending and strategic packaging. Each stage plays a vital role in ensuring product efficacy, consumer appeal, and brand differentiation. Below is an overview of the key phases involved in the pre-workout manufacturing process.

Research & Formulation

A successful pre-workout product begins with a science-backed formulation tailored to the performance needs of your target audience. It’s essential to use research-supported ingredients at clinically effective dosages to ensure efficacy, support structure/function claims, and build consumer trust.

Avoid “me-too” formulas by incorporating novel, evidence-based ingredients that differentiate your product. An experienced Contract Development and Manufacturing Organization (CDMO) can guide you through the research and formulation phase, helping you craft a formulation that aligns with your brand’s goals and stands out in a competitive market.

Ingredient Sourcing & Quality Control

To ensure product performance and regulatory compliance, sourcing high-quality, bioavailable ingredients is critical. Your pre-workout ingredients should be compatible with one another and align with your brand’s positioning, whether stimulant-based or stimulant-free.

While domestic sourcing may seem ideal, global ingredient selection is often necessary for optimal quality. For example, Ashwagandha sourced from India, its native region, typically offers higher potency and authenticity than domestic alternatives. A seasoned CDMO can help you identify and procure trusted raw materials from global suppliers while maintaining strict quality control protocols.

What Are the Main Ingredients in Pre-Workout?

There are many options for pre-workout ingredients to use in a supplement. Some of the more popular of these include the following:

Caffeine – Caffeine is commonly used as an energy and cognitive-promoting ingredient, as well as to help improve reaction time³ ⁴ ⁵⁶. It is available in both synthetic and natural forms.
Beta-Alanine –According to the International Society of Sports Nutrition,⁷ the results of beta-alanine supplementation include: 1) improved exercise performance, 2) attenuation of neuromuscular fatigue, and 3) possibly improvement in tactical performance. Overall, this amino acid helps increase exercise capacity and decrease muscle fatigue⁸ ⁹ ¹⁰ ¹¹.
Creatine Monohydrate – This tripeptide serves as an anabolic signal for muscle growth, acting as the chemical messenger that links increased muscle activity with the production of new muscle tissue.¹² ¹³ In addition, it may enhance post-exercise recovery, injury prevention, thermoregulation, rehabilitation, and neuroprotection.¹⁴
Branched-Chain Amino Acids (BCAAs) – Research has demonstrated that supplementation with BCAAs significantly reduced the breakdown of skeletal muscle in normal and exercising volunteers, ¹⁵ ¹⁶ ¹⁷ ¹⁸¹⁹ ²⁰ decreased muscle soreness and muscle fatigue occurring for a few days after exercise, ²¹ ²² and decreased lactic acid levels during exercise²³ ²⁴ ²⁵ ²⁶
Citrulline – This amino acid has been shown to significantly increase nitric oxide levels and physical performance markers while improving subjective feelings of muscle fatigue and concentration immediately after exercise. It’s also been shown to support healthy circulation.²⁷²⁸²⁹
B Vitamins (B3, B12) – Various B vitamins, including B3 and B12, play a vital role in energy production³⁰ and can be depleted during stress.³¹ Supplementation with B vitamins has been shown to help improve measures of stress, mental health, and vigor as well as improve cognitive performance.³²
Electrolytes – Sodium and potassium are electrolytes that can help replenish those lost during exercise and are more effective than water alone in maintaining hydration.³³³⁴
Black Ginger Extract – The polymethoxyflavones (PMFs) in this herb have been shown to improve cardiorespiratory fitness and physical as well as supporting muscle strength, endurance and speed ³⁵³⁶ ³⁷. PMFs from black ginger have also been shown to help in the reduction of abdominal fat and, more specifically, visceral fat.³⁸³⁹

Blending & Mixing

Various types of blenders (e.g., V-blender, ribbon blender, etc.) are used to mix raw materials. The correct amount of time in the correct blender helps ensure a uniformity of mix, which is also necessary to help ensure a finished product with the correct amount of each ingredient per serving. Additional steps such as fluid-bed agglomeration, granulation, and instantizing can help prevent clumping and enhance solubility and dispersibility for a smooth, easy-to-mix product. Not every CDMO can offer these particle engineering techniques, but Vitaquest has vast experience and capabilities in these areas.

Flavor Development

Flavor is one of the most critical first impressions a pre-workout product can make on the consumer. A well-flavored supplement encourages repeat usage and positive word of mouth.

Certainly, there is a wide range of flavors to consider. Citrus and berry flavors are common, or you may wish to consider other custom flavors based upon current trends or based upon the flavor that works best with the nutraceuticals in your formulation. This may include bitter masking agents if some of those nutraceuticals have bitter notes. Likewise, you can choose between natural, natural & artificial, or artificial flavors.

Working with a CDMO that has an in-house team of flavor formulators can give your brand a competitive edge because they possess the expertise needed to create a custom formula with a distinctive flavor profile tailored to your product and target audience.

Regarding sweeteners, you can choose natural or artificial options. If you choose sugar, be careful to keep its content relatively low, or it may be a deterrent to potential customers. Some options include:

Monk fruit and stevia – These natural sweeteners are sugar-free.
Allulose – A naturally occurring sugar found at low levels in figs, raisins, and other plants. It provides 0.4 calories/g compared to sugar, which has 4 calories/g. Because of the unique way in which it is metabolized, allulose is not required to be declared as sugar on labels.
Sucralose – A zero-calorie, artificial sweetener that is about 600 times sweeter than sugar.
Acesulfame potassium – A zero-calorie, artificial sweetener that is about 200 times sweeter than sugar.

Packaging & Labeling

Although most pre-workout supplements are manufactured as powders, they may also be produced as capsules, tablets, and in effervescent delivery systems. The way the final product is packaged will largely be based on the delivery form.

If you choose a powder, then the packaging will likely be a jar or canister with a measuring scoop. Powders can also be packed as convenient single-serving stick packs in jars or cartons. Capsules and tablets can be easily packaged in standard supplement bottles, jars, or blister cards. Effervescent tablets may also be packaged in standard bottles, jars, pouches, or in desiccated tube-type packaging (a/k/a vials).

Standard bottles, jars, and canisters are typically the most cost-effective packaging options, but your selection should align with your brand positioning, shelf presence, and logistics strategy. When it comes to supplement packaging, simplicity often wins—avoid overly complex designs that are difficult to open or take up excessive space on retail shelves.

Wrapping Up the Discussion About How is Pre-Workout Made

This article answered a popular question, “how is pre-workout made?”, offering a detailed, expert-level look at the full manufacturing process—from formulation and ingredient sourcing to blending, flavor development, and packaging. It covered how brand owners can develop science-backed formulas using high-quality, bioavailable ingredients and how CDMOs can play a key role in guiding formulation and flavor customization. The piece also highlighted the factors driving market growth, including rising consumer demand, the impact of wearable fitness devices, and the importance of creating a unique selling proposition.

Whether you’re a supplement brand owner looking to expand your product line or simply want to understand what goes into making a high-performance pre-workout supplement, this guide delivered the insights you need to navigate the competitive nutraceutical landscape with confidence.

Why Choose Vitaquest As Your Pre-Workout Supplement Manufacturer?

With over 45 years of experience, Vitaquest is a trusted Contract Development and Manufacturing Organization (CDMO) offering end-to-end solutions for supplement brands. Our turnkey services include expert formulation design, powder supplement manufacturing, packaging design, and advanced powder and particle engineering services utilizing technologies such as fluid bed processing, oscillation, and roller compaction. We also provide integrated supplement fulfillment solutions to help streamline your go-to-market strategy.

Whether you’re a newcomer to the industry or aiming to diversify your product range, Vitaquest possesses the expertise, cutting-edge facilities, and solutions needed to swiftly and effectively turn your pre-workout supplement concept into reality. Vitaquest also offers a variety of dosage forms, including capsules, traditional tablet supplements, chewable tablets, oral disintegrating tablets (OTD), and powders. In addition, you’ll benefit from an exceptional level of customer support, with a dedicated team focused on ensuring a seamless development and manufacturing experience from concept to commercialization.

Vitaquest also has expertise in domestic and international regulatory standards, as well as sustainability practices. Sourcing sustainable ingredients and using eco-friendly manufacturing processes can enhance brand appeal. Our FDA cGMP compliance, as well as third-party GMP certification from NSF, USP, and others, assures brand owners and consumers that we meet industry regulations and standards. Likewise, our ability to offer Kosher, Halal, and certified organic products, and FSSC 22000 certification for food safety are relevant certifications for manufacturing excellence.

Are you ready to capitalize on pre-workout supplements? If so, call 800-526-9095 to speak with one of our knowledgeable sales executives or request a nutraceutical manufacturing price quote if you’ve already finalized your project requirements!

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Frequently Asked Questions About Pre-Workout Supplements

How long does it take to manufacture a pre-workout supplement?

The process of manufacturing a pre-workout supplement varies. Project turnaround time is contingent upon the size of your order and the availability of the ingredients. On average, the first time around, it could take 12 weeks or longer since all the active ingredients will have to be sourced, and flavors will have to be decided upon, including taste-testing. After the first order is complete, reorders will go faster—maybe about 8 weeks.

Can I create a stimulant-free pre-workout?

Absolutely! If you want to promote energy/endurance, many ingredients can be used instead of caffeine. These include beta-alanine, creatine, citrulline, B-vitamins, and black ginger extract—to name a few. In addition, there is a broad range of other ingredients with value in a pre-workout. Examples included BCAAS and electrolytes.

What certifications should a pre-workout supplement have?

The most important consideration is for the pre-workout supplement to be manufactured in a facility with third-party GMP certification. The certification from NSF is considered the gold standard. A product can also be NSF Certified for Sport, which provides athletes, coaches, dieticians, and consumers with extra assurance about supplement safety.

How do you ensure the quality and safety of pre-workout supplements?

To help ensure the quality and safety of a pre-workout supplement, it should be manufactured by a GMP-certified facility that has been audited for cGMPs by a credible third-party agency, ensuring compliance with industry standards. Among the best of the GMP certifications is NSF-GMP certification. Another consideration is the rare but globally recognized standard in the food and supplement industry, known as FSSC 22000 certification for food safety.

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Rick

Handel

Senior Vice President of Commercial Operations

Rick Handel is a 50-year veteran of the nutraceutical industry, with a strong background in formulation, R&D and GMP manufacturing of dietary supplements. Rick is celebrating 30 years with industry-leading supplement manufacturer Vitaquest International, where he currently serves as Senior Vice President of Commercial Operations. In that capacity, Rick is responsible for driving sales and innovation by identifying and developing new strategies, business opportunities, science-backed ingredients, and novel delivery technologies. Rick holds eight patents and has presented his published scientific papers and studies at conferences around the world.

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