A Q&A with our Head of R&D, Jess Cerra
ICYMI: We just launched electrolyte gummies.
And, yeah, they’re a big deal. A “category defining breakthrough" big deal, to quote our CEO.
That's because they deliver a unique combination of:
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A meaningful amount of electrolytes based on what you lose in sweat – existing options had little to no sodium content, which is the leading electrolyte lost in sweat
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Clean ingredients – meaning no artificial sweeteners and no sugar alcohols
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Taste that delivers – a SaltStick fundamental
They’re so unique, in fact, that our formulation is patent pending.
But like most innovation, it wasn’t easy. We spent over a year and more than 35 rounds of testing to create a product we’re truly proud of. One that meets the SaltStick standard for science-backed innovation, convenience, and irresistible taste.
How? We sat down with Jess Cerra, who leads our product development, to go behind the scenes of how electrolyte gummies came to life.
In this Q&A, you’ll learn:
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Why we built an electrolyte gummy
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Why an effective electrolyte gummy was so difficult to create
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How SaltStick tests and validates new products
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Whether Pickle FastChews are ever happening
Let's start at the beginning. Why create an electrolyte gummy?
Jess: Why not create one?!
We make chewable electrolytes. We love making delicious gummies. It seemed almost irresponsible not to combine two of the things we do best.
A more nuanced answer is that when we surveyed the market for electrolyte gummies, we realized there wasn't an option that combined meaningful, efficacious electrolyte levels, clean ingredients, and a truly enjoyable gummy experience. We knew we could create a product that was more effective, more flavorful, and aligned with everything SaltStick stands for.
Walk us through that initial research and development phase. What does designing a brand-new product actually look like?
Jess: At SaltStick, we have a structured process that takes an idea from a brainstorming session to, "Yes, this is a product we want to launch."
First, we pressure-test the concept. We don't develop products simply because they're trendy. If a product can't be backed by science, we're not interested. If we have to compromise on ingredients, we’re not interested. And if it's not something we're genuinely excited to use ourselves, it doesn't move forward.
Once we believe we have a strong concept, we turn to our athlete community. We gather feedback on the idea to make sure it’s meeting a genuine need. The goal is to create products that people trust—but also can't wait to eat/use.
Then comes my favorite part—bringing it to life in the R&D lab!
For the electrolyte gummies, that last step took more than a year.
Over a year? Why was it so hard to make these gummies?
Jess: There's a reason a product like this hasn't really existed before. It's incredibly challenging to incorporate meaningful amounts of electrolytes into a gummy while still delivering great taste, an enjoyable texture, and a manufacturing process that can be repeated consistently at scale.
Our formula went through countless revisions. We delayed our launch multiple times because we refused to compromise on the things that matter most: quality, flavor, texture, label claims, and the overall athlete experience.
I can tell you there were a couple of prototypes that I had convinced myself were the one. But that's exactly why we have a structured development process. Once we put those samples in front of our athletes to get their feedback, I had to take a step back, trust the data, and continue working to make the product even better. I'm an "all gas, no brakes" kind of athlete, so personally that was the most challenging part of the process.
In the end, it was worth it. The meticulous refinement phase made us realize that we had developed something truly novel. So, another exciting part of this process was filing for a patent! We’re incredibly proud to say that the final product is now patent-pending.
How many rounds of testing did it take to land on the final formula? Who's involved in the testing, and what kind of feedback are you looking for?
Jess: More than 35 rounds! It sounds a little crazy, but getting the flavor right was incredibly important to us.
For Raspberry Lemonade alone, we tested around a dozen different lemon and raspberry flavor systems and combinations. Most people don't realize that two natural lemon flavors (meaning they contain the actual fruit) can taste completely different. It's honestly one of my favorite parts of product development—it's like solving a delicious puzzle.
But testing doesn't stop with our R&D team. We involve our staff, members of our Sweater Crew ambassadors, and even people who have never tried a SaltStick product before. Each group gives us a different perspective.
We're asking a variety of questions:
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Does it taste good?
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Is it too sweet or not sweet enough?
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Is the texture just right?
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Would you actually buy this product?
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What would you change?
Then there's what I call the "real-world test." We throw the products in our gym bags, leave them in hot cars, take them on long bike rides, stuff them in running vests, and generally treat them the way our athletes will.
And finally, we validate everything scientifically. Every formulation undergoes laboratory testing to confirm the electrolyte levels match our label claims, and the gummies also complete stability testing to ensure they'll perform throughout their shelf life.
By the time a gummy makes it into someone's running pack or jersey pocket, it has been challenged from just about every angle we can think of.
Pictured above: Our head of product development, Jess Cerra, sits with about half of the samples we tested before landing on the final product!
How are you personally using these in your own daily life and training?
Jess: Honestly, I'm probably the ultimate test athlete.
Most weekends I'm out riding 10–12 hours on the bike, or I'll head out for a 10–15 mile trail run with my dog, followed by a long ride the next day.
If there's a way someone might carry these, I've probably tested it. Tubes, pouches, bags, jersey pockets, running vests, you name it. They've survived hot cars, freezing ski days, mountain bike rides, gravel adventures... basically every environment I could think to throw at them. During the prototype phase, they practically lived in my ski jacket for the month of March.
And a final question for the people... will Pickle FastChews ever happen??
Jess: I can’t comment on that one yet, but trust me, if you’re a pickle fan, we see you. You’ll just have to stay tuned.
