Gummy Vitamin Line Production Increase

Nutraceutical Manufacturer

Highlights
  • Simultaneous production of multiple colors and flavors
  • Installation of two corn syrup tanks, seven conditioning rooms, and safety access platforms
  • Construction management and fast-track scheduling

Southeast USA

SSOE has documented nearly $2 million in savings, including $1.6 million for the AMS upgrade project, $153,000 for the tray washer project, and $101,000 for the first set of conditioning rooms, corn syrup tanks, and kitchen platforms.

To keep up with consumer demand, a leading nutraceutical manufacturer needed to double its current gummy vitamin production capacity—increasing the current production area by approximately 8,200 SF. SSOE led the design for simultaneous production of multiple colors and flavors, which required modifications to the up front unit operations and an upgrade to the existing Additive Mixing System (AMS). Installation of bulk truck unloading transfer piping with heat tracing and two new 5,000 gallon corn syrup tanks was also included in the project scope. To allow for the capacity increase, SSOE designed expansions to the manufacturing area, seven new conditioning rooms, and a mezzanine to support a new heat exchanger without taking up valuable floor space. Our structural team designed safety enhancements in the kitchen areas by designing new access platforms. Additionally, SSOE designed a new COP room to accommodate new tray washing equipment to satisfy the flow of operations.

SSOE’s structural, process / utilities, mechanical, and electrical disciplines provided a wide range of engineering services for process design and equipment layout. Our project management team provided the project budget development and installation schedule, and oversaw contractor bid reviews and vendor drawing reviews. We also provided construction management services to reduce the cost of hiring general contractors and matched hours to suit the project schedule needs.

Due to delayed equipment arrival, the SSOE project team needed to quickly adjust to a “crash schedule” as the project moved toward completion. Understanding the urgency for speed to market, SSOE’s on-site construction management personnel worked weekends, holidays, and extended work week hours to meet the client’s desired completion date.

SSOE has since provided ongoing design and engineering services for this client, supporting the manufacturing of a variety of gummies including prenatal and food-based vitamins as well as fiber supplements.

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