Synergy Health Labs, located in Tampa, FL, is a leading manufacturer specializing in vitamins, minerals, herbs, and an extensive range of health, wellness, and sports supplements.
When Synergy Health Labs began experiencing exponential growth, the company’s existing equipment could not keep up with demand, resulting in poor packaging quality. A substantial order of half a million bottles had to be recalled due to safety seal issues, posing a significant challenge to the company. Additionally, the shrink packaging and inkjet coding processes were causing persistent problems. Shrink sleeves were not consistently applied to bottles, requiring frequent manual adjustments. The existing inkjet printer, a low-quality Chinese CIJ Model, was also causing operational disruptions.
To help Synergy Health Labs quickly and efficiently handle their recent recall, Alpha Industrial Supplies proposed an innovative solution – the installation of an AFM Steam Tunnel. After careful product testing and a visit to the AFM facility in Minnesota, the Synergy team selected AFM’s WSN Series Steam Heat Tunnel. The steam tunnel offered adjustable mandrills, enabling precise control over heat for a proper seal without compromising the sleeve’s integrity.
Additionally, the company’s previous CIJ printer was replaces with a Videojet 1580. This upgrade reduced maintenance requirements, eliminated core replacements, and significantly increased overall uptime.
By implementing the AFM Steam Tunnel, Synergy Health Labs experienced remarkable improvements in their production lines. The rework of half a million bottles was completed in approximately 80 hours, demonstrating a significant reduction in downtime. Moreover, Synergy Health Labs experienced a 40% increase in overall packaging capacity, setting their team up for sustainable future growth and opportunities.