Kaitlyn McCammack, Manager of Research and Development at LaCore Nutraceuticals, takes us behind the scenes of their Van Alstyne, Texas facilities to explore cutting-edge beverage manufacturing and discuss the CREATEA Mighty Mango collaboration on Episode #194 of the PricePlow Podcast.
Welcome back to Episode #194 of the PricePlow Podcast, where we tour LaCore Nutraceuticals in Van Alstyne, Texas with Kaitlyn McCammack, their Manager of Research and Development. Fresh off running the CREATEA Mighty Mango beverage -- the collaborative innovation featured at SupplySide Global 2025 -- we explore LaCore's impressive manufacturing capabilities and discuss why creatine belongs in functional beverages.
LaCore represents a rare breed in supplement manufacturing: a facility offering everything from personalized nutrition packs to 12-ounce cans, stick packs to tetras, all while maintaining startup-friendly minimums. Katie walks us through their two Texas facilities, including a nostalgic former Johnson & Johnson building housing their can line with the biggest tanks we've seen. The conversation ranges from creatine for kids to liposome technology, proving that manufacturing innovation drives ingredient innovation.
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https://blog.priceplow.com/podcast/lacore-nutraceuticals-194
Video: Behind the Scenes at LaCore Nutraceuticals in Van Alstyne, Texas
Podcast: Play in new window | Download (Duration: 49:45 — 50.8MB)
Detailed Show Notes: Manufacturing Innovation with Kaitlyn McCammack
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0:00 - Introductions and LaCore's Multi-Format Capabilities
Ben welcomes Kaitlyn (Katie) McCammack, Manager of Research and Development at LaCore Nutraceuticals, joined by guest host Joey Savage. Katie describes LaCore's comprehensive manufacturing approach: "We do everything except softgels and gummies" -- including multi-serve powders, stick packs, liquid sticks, gel packs, 12-ounce cans, and soon-to-launch tetra packs. The team had just witnessed the CREATEA Mighty Mango production run, culminating months of collaborative innovation.
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1:45 - Tour of the Van Alstyne Facility
The conversation shifts to LaCore's unique facility in Van Alstyne, Texas -- a former Johnson & Johnson building from the 1970s. It's descrdibed as authentically retro with vintage tiles, a full cafeteria, locker rooms, and even childcare facilities, calling it "like walking through a time capsule." The nostalgic architecture contrasts with cutting-edge beverage manufacturing capabilities, featuring the largest mixing tanks the team has encountered and an analog pneumatic can line with character and personality.
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3:30 - Production Scale and Startup-Friendly Philosophy
Katie explains LaCore's efficient tote method that doubled their canning output while maintaining accessibility for emerging brands. While many manufacturers require million-unit minimums for cans and tetras, LaCore accommodates startup-friendly runs as low as 25,000 units. Their collaborative philosophy: help brands innovate and grow, even if success means they eventually outgrow LaCore's capacity. The hands-on approach includes engineers actively monitoring production runs and troubleshooting in real-time.
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6:15 - The CREATEA Project: Bringing Creatine to Functional Beverages
Katie recounts Joey approaching her months after SupplySide about collaborating on a creatine energy drink, admitting she threatened to "slash George's tires" to ensure Glanbia Nutritionals committed. The development process proved surprisingly smooth thanks to CreaBev dissolving perfectly in liquid. Katie expresses enthusiasm about showcasing creatine for mental focus and clarity rather than just muscle building, noting the ingredient is "having its moment" beyond the traditional muscle-head demographic.
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8:00 - Katie's Personal Creatine Protocol
Katie reveals she gives her four-year-old daughter one gram of creatine daily, noting visible differences in cognitive performance on days when she takes it versus when she doesn't. At three and a half feet tall, her daughter is the biggest kid in her class and highly active in sports. Katie reflects on creatine's evolution from "muscle-head central" when she entered the industry seven years ago to today's broader recognition of cognitive and health benefits.
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10:45 - Creatine Dosing Strategy and Overages
The discussion turns technical regarding CREATEA's creatine content. While labeled at 1,500 milligrams, attendees at SupplySide were actually receiving five grams due to creatine monohydrate conversion factors and manufacturing overages. They wanted an even higher "mega dose" initially, citing recent 20-gram studies showing benefits for sleep-deprived individuals. Katie's one-gram protocol for her daughter aligns with expert recommendations for young children's brain and muscle development.
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13:15 - Creatine Research Beyond Muscle Growth
Joey discusses recent conversations with creatine researcher Rick Kreider about perinatal use and safety across the lifespan. Multiple studies now support creatine supplementation throughout pregnancy, including research extending through the third trimester. A summer 2024 study from Spain demonstrated creatine's effects on reducing anxiety and gut inflammation, expanding the nutrient's applications well beyond traditional workout recovery and muscle building.
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15:30 - Bringing Creatine into the Cognition Space
The team positioned CREATEA in the cognitive enhancement category because mental benefits are noticeable acutely, unlike gut inflammation or other effects requiring longer timeframes. After drinking the beverage that morning, Joey questioned whether he was feeling the creatine or the Zynamite. Ben notes wishing they could return to proprietary blends so people would try products before judging based solely on label panels, as CREATEA delivers noticeable effects despite unconventional dosing.
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17:15 - Can Size Preference and Industry Trends
The conversation turns to beverage formats, with Katie noting 16-ounce cans are challenging to finish compared to more approachable 12-ounce sleek cans. Multiple participants admit to desks littered with half-finished larger format drinks. Joey observes the 12-ounce trend gaining momentum across the industry, with brands recognizing consumer preferences for complete consumption. The format discussion connects to broader conversations about convenience and user experience in functional beverages.
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19:00 - Energy Drink Preferences and Market Positioning
When asked about traditional Monster Energy drinkers, Katie diplomatically suggests they're either "desperate or uncultured," preferring Monster's Zero Ultra line herself. The casual banter highlights evolving consumer sophistication around ingredient panels and formulation quality. Discussion shifts to CREATEA's positioning as a "nobody unless you come to SupplySide" exclusive, creating buzz and demand through limited initial availability similar to coveted sneaker drops.
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21:30 - Personalized Nutrition and Pack Customization
Ben circles back to the impressive personalized nutrition system they toured earlier. LaCore's capabilities include creating fully customized supplement packs based on DNA analysis or programmatic needs, with each individual packet containing unique ingredient combinations. The technology shocked both Ben and Joey initially, representing a sophisticated approach to addressing individual nutritional requirements rather than one-size-fits-all supplementation.
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23:45 - Multi-Serve Liquids and Format Innovation
Katie clarifies "multi-serve liquids" as products like liquid L-carnitine or Mary Ruth's collagen -- bottles containing 30 servings with 15ml teaspoon-sized doses. LaCore currently handles cold-fill multi-serve liquids with plans to add hot-fill capabilities in 2025. These formats appeal to consumers preferring liquid delivery over powders while maintaining cost-effectiveness compared to single-serve options.
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26:30 - Gel Packs, Liquid Sticks, and Novel Delivery Systems
The team explores LaCore's gel pack and liquid stick capabilities, with Joey suggesting applications like glycerol boosters at gym front desks or caffeine-free energy drinks sold alongside caffeine stick boosters. Katie describes liquid stick production flexibility, noting they can formulate virtually anything into the convenient format. The discussion sparks creative ideas around "booster bars" and convenient supplementation solutions for active consumers.
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30:30 - Liposome Technology and Particle Size
Joey dives into liposome manufacturing, explaining the protective phospholipid bubbles that help ingredients survive stomach acid. Key considerations include loading capacity, phospholipid composition, solubility, and achieving optimal particle size. He predicts liposomes will be "the year's trend" at SupplySide, followed by competitive battles over who can achieve the smallest particle sizes for maximum tissue penetration.
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33:00 - Homogenizers vs. Sonicators
The technical discussion continues with particle size reduction equipment. Katie clarifies they use homogenizers rather than sonicators for reducing particle size before liposome formation. Smaller particle sizes increase surface area exposure, critical for effective encapsulation. Joey explains the process of mixing powders with oils under sonication, emphasizing the importance of starting with the finest possible particle size.
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35:15 - Emulsion Technology and Novel Applications
Joey describes emulsion technology as "making oil and water mix," enabling delivery of high-dose ingredients like fish oil in gel shots rather than traditional softgels or liquid bottles. The team brainstorms applications including sunscreen sticks, convenient ketchup-mustard style vitamin dispensers, and beach-friendly supplement delivery systems. LaCore's capabilities span from traditional formats to cutting-edge convenience solutions.
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38:30 - Clean-in-Place (CIP) Procedures
Katie explains CIP (Clean-in-Place) protocols, standard operating procedures critical for maintaining manufacturing integrity. Probiotic and spore-based supplement runs require particularly intensive cleaning because spores can survive extreme conditions -- radiation, heat, pH changes -- potentially contaminating subsequent production runs. While LaCore doesn't frequently manufacture probiotics anymore, they maintain the capability with appropriate safety protocols.
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41:00 - Rev7 Ketone Beverage Sampling
The team samples Rev7 from Ketone Labs, a strawberry peach flavored ketone beverage featured in PricePlow's article on stimulant-free energy drinks with BHB. The naturally sweetened formula uses citric acid instead of phosphoric acid, delivering a juicy peach profile. Katie notes the flavor work by Bell Flavors, praising the peach's authentic juiciness that avoids the dry, mealy character common in peach-flavored supplements. The ketone-based energy appeals as an alternative to caffeine-heavy options.
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43:30 - Arjuna's Shoden Ashwagandha Innovation
Katie introduces a pineapple-flavored ashwagandha beverage from Arjuna featuring Shoden, their glycoside-enhanced ashwagandha extract. At just 75 milligrams, the higher standardization delivers effective doses for mood support and stress management in a clear, refreshing beverage. Katie recalls being amazed watching it dissolve during development, as ashwagandha's solubility historically limited beverage applications. The product represents Arjuna's vision for an everyday wind-down or mood-supporting drink.
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45:30 - Facility Capabilities and Industry Positioning
Joey marvels at LaCore's comprehensive capabilities under one roof: cans, tetras, gel packs, liquid sticks, stick packs, powders, capsules, and more. The diversity of dosage forms distinguishes LaCore from single-format specialists, enabling brands to develop complete product lines with a single manufacturing partner. Katie emphasizes that LaCore remains a "hidden gem" in the industry, with founder Terry valuing innovation and investing in diverse equipment to support creative formulation.
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47:00 - Katie's Industry Journey and SupplySide Preview
Katie shares her "fangirl moment," reflecting on sitting with industry leaders she never imagined meeting face-to-face when entering the supplement space seven years ago. She'll attend SupplySide Global with LaCore's Director of Global Supply Chain and Procurement, eager to showcase their capabilities. Katie praises PricePlow for "bringing back what this industry used to be about" -- collaboration, education, and innovation rather than cutthroat competition.
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48:30 - Closing and SupplySide Innovation Stage
The team confirms plans for the SupplySide Innovation Stage panel on Wednesday at 3pm, followed by a cocktail hour celebrating the CREATEA collaboration. The episode concludes with excitement for continuing the industry's collaborative innovation momentum in Las Vegas.
Where to Follow Kaitlyn McCammack and LaCore Nutraceuticals
- Kaitlyn McCammack on LinkedIn: https://www.linkedin.com/in/kaitlyn-mccammack-37656a178/
- LaCore Nutraceuticals on LinkedIn: https://www.linkedin.com/company/lacorenutra/
- Sign up for LaCore Nutraceuticals alerts: https://www.priceplow.com/lacore-nutraceuticals
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