Case study

Established Vitamin and Supplement Manufacturer

A well-established contract manufacturer of vitamin and mineral supplements in various formats, including tablets, capsules, and powders. With over 15 years in the industry, they serve numerous national brands but faced increasing competition from newer facilities with more modern equipment.

project stats

Service:

Engineering, Procurement, Installation

Industry:

Vitamin & Supplement Manufacturing

Location:

Arizona, USA

Challenge

Outdated Equipment Compromises Competitive Position

This supplement manufacturer needed to modernize their powder filling operation to remain competitive. Their existing equipment was inefficient, with frequent breakdowns causing production delays and inconsistent fill weights leading to product waste. They needed a solution that would improve quality, increase throughput, and reduce downtime, but were concerned about integration with their existing systems and potential production interruptions during installation.

Solution

Phased Modernization Plan Minimizes Disruption

SW Equipment Group developed a comprehensive modernization plan:

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  1. Engineering: Conducted a thorough front-end engineering study to identify all integration points and potential challenges
  2. Procurement: Sourced a new servo-driven auger filler with advanced controls for precision dosing, along with updated conveying and inspection equipment
  3. Installation: Created a phased implementation schedule that minimized production disruptions, with installation teams working during planned downtime

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Result

85% Faster Production with 65% Less Variability

The modernization project delivered immediate benefits:

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  • Reduced fill weight variability by 65%, significantly decreasing product giveaway
  • Increased line speed by 85% while improving accuracy
  • Decreased changeover time between products by 50%
  • Reduced maintenance downtime by 70%, improving overall equipment effectiveness
  • Enhanced ability to compete for and win new business
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"Our outdated equipment was holding us back in an increasingly competitive market," explains the Production Manager. "SW Equipment Group didn't just replace our old machines—they reimagined our entire process. Their end-to-end approach made a complex modernization project manageable and delivered results that exceeded our expectations."

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