I have to sympathize with the difficulty Rosa Foods faces in re-introducing the bar. First is the matter of making damn sure the bars are wholesome, which means, first, reformulating to not use the algal material. That's not easy; every little change in ingredient affects the taste and the texture, leading to another round of testing.
Then, I would bet they will want also to find a different co-packer, and that is a long process of research and inspecting and negotiating costs. On top of that, there aren't all that many candidate co-packers, and some may be leery of associating with the company that made the "barf bar". From their standpoint, if RF doesn't get the new formula right, and there's another round of digestive problems and bad press, their reputation takes a hit, too.
Then there is the whole question of how to handle the press. Remember the blizzard of awful headlines they had to weather? Every headline-writer in the world searched their thesauri to find synonyms for "puke" and "diarrhea", to produce gleeful "clueless techies made a barf bar, yuck yuck" stories, day after day. It was schadenfreude city for weeks.
All of that will be recalled and re-hashed when the bar is announced. RF and their advertising consultants are probably working hard to find ways to pre-empt that. Probably they are looking for ways to make the bar different from before: new packaging? new size? multiple flavors? Anything to divert attention from the past! If they just bring back the same shape and package as before, there will be nothing for journalists to write about except the old barf stories.
But thinking up ways to make the product visibly different in an interesting way, adds to the complexity of the job. Different flavors especially would take a long time to formulate and test.
Huh, suddenly as I'm trying to think, what could they do differently, I flashed on the image of a bar that is divided into snap-off sections, like a Toblerone. That would be a cool differentiator, eat it all or break off a100-calorie chunk. RF, you're welcome.