Faced with the rising demand for gummy supplements, Ion Nutrition Labs knew they needed to scale up quickly to stay competitive. With 350 employees across two facilities, they already produced a range of nutraceutical products but required a high-speed gummy production line to meet growth targets. That’s when they turned to BW Integrated Systems for help.
In this blog post, we share how Ion Nutrition Labs approached the production line expansion, how BW Integrated Systems and their Integrated Packaging Solutions (IPS) team provided them with a custom-fit solution, and the successful results of the new, completely integrated gummy packaging line. If you want to see the story in a video format, watch the Ion Labs Customer Testimonial video above.
The Search for the Right Partner
Ion Labs knew they couldn’t take on the expansion alone—they needed a partner they could trust. That's when they turned to BW Integrated Systems (BWIS). Matthew Keib, Ion Nutrition Labs Chief Operating Officer (COO) was impressed with BWIS’ expertise, their ability to act as a single point of contact throughout the project, and their US-based support.
“I wanted one company that I was working with, building that relationship with, and having that communication,” Keib explained. “Customer service in the US was very important to us.”
From the start, Ion Labs felt confident in BWIS’ approach. Not only did BWIS come in early to understand Ion’s goals, but they also provided reassurance that they could deliver the ideal solution to meet their high expectations. BWIS’ IPS team played a key role in this collaboration by managing the entire packaging line integration, coordinating with multiple OEMs to ensure seamless functionality, and streamlining the process for Ion Labs.
“They expressed to us that they really wanted to improve the level of automation and efficiency on this line,” said David Duff, Sales Executive at BW Integrated Systems. “We brought them in and provided a lot of confidence that we could integrate the equipment from OEMs they selected and have it run efficiently.”
A Collaborative Journey
Despite facing a major challenge – the new gummy line had to fit into a very tight footprint within the existing facility – BWIS rose to the occasion. The IPS team worked through a collaborative process to design a layout that not only fit the space but delivered incredible efficiency.
“They developed a line that not only could maintain the speed, offer full integration, and squeeze it all in,” said Jamie Mireles, Maintenance Manager at Ion Labs. “They were able to pull it off and do it well. They did amazing.”
Beyond adding new machines, the expansion project focused on building trust between the two teams. The IPS team ensured that Ion Labs had full visibility into the project by offering clear communication at every step, acting as the primary liaison with OEMs, and providing a dedicated project manager to handle any concerns. Their streamlined approach minimized complexity and allowed Ion Labs to stay focused on their production goals.
The Results: Confidence and Growth
With the new line in place, Ion Labs is now prepared for the next five to 10 years of growth. Their gummy production is faster, more automated, and ready for the future. The new system also provides their team with renewed confidence in their ability to meet growing demand.
“The line is state of the art,” said Jean Ramirez, Gummy Manager at Ion Labs. “It helped me as a manager to have better control of the process and make sure I’m packing a good, quality product and hitting my performance goal.”
The collaboration with the BW Integrated Systems IPS team helped Ion Labs achieve their vision, no matter the challenges they faced along the way. With the seamless integration of equipment and full support from the IPS team, Ion Labs is ready to tackle the future and continue their journey of growth.
Learn More about Ion Labs’ Story and BW Integrated Systems
Ion Labs’ new gummy line helped them stay competitive and keep up with demand while maintaining cost-effectiveness. Want to learn more about their success story? Click here to read the full case study.
If you’re ready to transform your own packaging line with a custom solution, reach out to BW Integrated Systems today!