Eliminating granule degradation, ensuring strict FDA counting compliance, and slashing labor-intensive changeovers for a leading North American nutraceutical brand.
Top-Tier Nutraceutical Contract Manufacturer (OEM)
Premium Dietary Supplements & Vitamins
Child-Resistant Rigid Bottles & Doypacks
FDA cGMP
May 2025
$280,000+
California, USA
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The client, operating in a highly regulated and high-labor-cost facility in California, was struggling with their legacy supplement packaging lines. They faced three critical operational bottlenecks:
High-Risk Counting Non-Compliance : Mechanical counting wheels suffered from double-feeding on sticky softgels. In the US market, incorrect bottle counts trigger severe FDA warnings and costly full-batch recalls.
Crippling Labor Costs During Changeovers: With hourly wages soaring, spending 2+ hours using mechanics with wrenches to switch from freeze-dried granules to vitamin pills was financially unsustainable for their high-mix operations.
Granule Degradation: Aggressive vibratory feeders crushed high-value, fragile botanical granules, generating unacceptable dust levels and compromising product aesthetics.
Prior to shipping, the integrated line underwent a rigorous Factory Acceptance Test (FAT) to guarantee it met the client’s strict SLA metrics:
EIXPACK engineered a modular, ultra-hygienic hybrid filling architecture compliant with strict North American safety and sanitary standards.
We deployed a high-speed electronic counting matrix equipped with intelligent dust-compensated infrared sensors. The system cross-checks pill geometries in mid-air, automatically ejecting mistitled or broken capsules before they enter the bottle.
For delicate granules, we replaced rotary scrapers with a servo-controlled telescopic sliding cup mechanism. Granules are discharged purely via gravity with zero mechanical shearing.
To combat high labor costs, all material-contact parts—including dosing tracks and counting funnels—are secured via quick-release pneumatic locks. Operators can swap formats entirely by hand.
Following complete line integration and operator training in California, the client documented immediate financial returns:
Zero Compliance Fines: 100% accurate count validation eliminated FDA audit risks and potential consumer lawsuits.
Labor Costs Slashed: Sub-10-minute tool-less changeovers eliminated the need for dedicated mechanics during product switches, saving an estimated $65,000 annually in labor and downtime.
Premium Quality Secured: The gravity-fed system protected fragile herbal granules, elevating the brand’s premium unboxing experience.
Every EIXPACK electronic counting machine is built utilizing 316L mirror-polished stainless steel on all contact parts to eliminate cross-contamination. Our control cabinets feature UL-certified electronics, and our PLC software can be upgraded to comply with FDA 21 CFR Part 11 for electronic records and signatures, ensuring complete audit traceability.
No. Conventional counters fail when dust coats the sensor lenses. EIXPACK systems utilize a proprietary high-frequency infrared optical array with active automatic dust-compensation intelligence. The system continuously recalibrates its baseline, meaning airborne dust will never cause missing pulses or inaccurate bottle counts.
Conventional auger fillers apply mechanical shear stress that crushes fragile botanical granules. EIXPACK solves this by deploying a servo-driven volumetric sliding cup system. The granules drop purely via gravity into telescopic chambers, eliminating mechanical friction and bringing the material damage rate to 0%.
North American facilities cannot afford hours of labor-intensive downtime. EIXPACK designs out the bottleneck with a 100% tool-less architecture. Operators can easily unlock pneumatic clamps to remove counting funnels and dosing tracks, performing a complete sanitary format changeover in under 10 minutes without needing a wrench.
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