Scaling Up Production by 200% for a Global Supplement Brand

When a rapidly expanding international supplement brand faced severe supply bottlenecks, Agnivesh re-engineered their manufacturing workflow, scaling batch volume by 200% while reducing lead times by 35% via our contract manufacturing infrastructure and high-capacity bulk supply capabilities.

200%
Scale
Zero
Defects

The Challenge

The client, an established direct-to-consumer nutraceutical brand with distribution across North America and Europe, experienced unprecedented demand following their clinical efficacy campaigns. However, their existing manufacturing partner was unable to fulfill orders beyond 150,000 units per month, leading to recurrent out-of-stock situations and lost retail shelf space.

Key constraints included strict multi-mineral tablet formulation sensitivities, delicate enteric coatings, and tight regulatory compliance deadlines for European export batches.

Our Technical Solution

Agnivesh initiated a dedicated three-tier engineering intervention to scale the production line:

• Automated High-Speed Rotary Compression: Deployed high-tonnage 45-station rotary tablet presses capable of maintaining uniform hardness and friability tolerances at high speed.
• Continuous Perforated Pan Coating: Integrated automated spray coating systems that reduced cycle time by 40% while achieving ultra-uniform gastric resistance.
• Integrated Robotic Blister & Bottle Line: Synchronized primary and secondary packaging with real-time vision inspection for lot verification.

The Commercial Impact

Within 90 days of onboarding, the brand successfully eliminated backorders, expanded into 350 new retail doors in the EU, and achieved an estimated 28% reduction in unit manufacturing cost due to bulk material optimization.