Interview with Gabriela Kostuchowska- Product Development Specialist at the Research and Development Department

Gabriela, you have worked at Aerosol Service for many years. How did your history with the company begin?

I am originally from Koszalin, but for many years I lived and worked in Sandomierz, where I was a biology teacher. I majored in biology at the Nicolaus Copernicus University in Torun, but after a few years at school I realized that this was not my calling. I returned to Pomerania and, after brief episodes in various industries, ended up at Aerosol Service. I started as a quality controller on the production line, then worked in the Quality Control Department, and today I am a product development specialist in the Research and Development Department. This is where I am in charge of developing new formulations and technologies.

How has the company changed from your perspective - especially in terms of R&D?

We have taken a huge step forward. When I started, we produced only aerosols - mainly household and technical chemicals. Cosmetics were only a small part. Today they dominate, and mainly in the form of liquids. At the same time, the complexity of formulations and processes has changed - today they are much more advanced.

The laboratory has also undergone a transformation. There used to be three to four people working there with basic equipment. Now our team has a dozen people, and the equipment we have at our disposal allows us to conduct more precise and complex analyses. We have to study more parameters, because market and regulatory requirements are much higher than they used to be. We also spend a lot of time analyzing new legal and environmental regulations.

What exactly is your role in R&D?

My main task is to create formulas. Usually the process starts with a client's idea - then we work on the appropriate formulation. I develop and optimize the composition of products so that they meet specific functional, technological, quality and regulatory requirements. Formulation development is largely intuition and experience - this cannot be learned from a textbook, you just have to feel it.

What does the entire process of creating a new product look like - from idea to implementation?

We start by creating a formulation and performing the first tests in the laboratory. Then we refine the formulation, conduct stability and compatibility tests. The next step is microbiological testing - we send samples to accredited laboratories, which confirm that the product is microbiologically pure. Next, the product undergoes dermatological evaluation - we check that the product is not allergenic and does not irritate the skin. The final stage is maintenance testing, known as challenge testing. The whole product has to go through rigorous procedures before it goes into production. The last stage is the so-called "scale-up," which is the transfer of the process and technology from the laboratory scale to the production area. 

Is there a project you are particularly proud of?

Definitely yes - one of my favorite projects was the design of Pantenol spray foam, a product to soothe burns. I developed it independently from start to finish. Equally important was an alcohol-based hand sanitizing foam - this was a huge technological challenge, because alcohol "quenches" the foam. I spent a lot of time searching for raw materials that allowed the foam to remain durable. A unique project was also Pianolina - an innovative product for children, with unique scents and colors.

What competencies are key to working in R&D today?

The most important thing is passion and interest in cosmetics. You need to be determined, not to give up when something doesn't work out. Contrary to what you may think, knowledge of chemistry or biology is not crucial - commitment and openness to new solutions are much more important.

In what direction will the industry and the R&D department itself evolve?

Definitely towards innovative, ecological and natural products. The market expects distinctive, but also safe and environmentally friendly solutions - a trend that will only grow stronger.

What gives you the most satisfaction at work?

Sense of agency. My greatest joy comes when I see "my" product on the store shelf. When orders are repeated - this is the best proof that the recipe was a hit. Great satisfaction also comes from translating laboratory work into large scale - preparing the product for mass production. And, of course, the people - I have a great team with whom we share experiences and together look for the best solutions.