MONTREAL, May 19, 2022 – 21st Century HealthCare is a top manufacturer of high quality vitamins and supplements dedicated to producing the safest and most reliable wellness formulations. This commitment to quality helps drive their success. Over the past several years, 21st Century earned double digit annual growth and, to keep pace, expanded production last year. They turned to NJM, a ProMach product brand, and installed a high-performance integrated bottling line in 2021.
“With this new packaging line, we wanted to increase throughput, improve efficiency and ease changeover while maintaining the highest product quality. We knew that NJM would give us everything we wanted and more,” said Favio Contreras, Chief Operating Officer at 21st Century. “Having a fully integrated line ensures the machines all work together seamlessly, which eases installation and improves performance. Giving that responsibility to NJM means we get the best technology and their great service.”
“We’re achieving roughly 25 percent more uptime on this new line than any of our other lines. With such high output, our line operators feel even more accomplished at the end of each shift, which is great for morale. And that high output also allows us to fulfill customer orders quickly,” explained John Horsefield, Vice President of Operations at 21st Century. “We package close to 3,000 different bulk tablets, capsules and softgels in a variety of bottle shapes and sizes, cap styles and label configurations. By design, our new packaging line can handle it all.”
“We run this line 20 hours per day and try to schedule no more than six changeovers in a week. With so many different products, it’s important that our changeovers are fast and easy. It takes only 30 minutes to fully changeover this line – that includes cleaning the line during a formulation change as well as changing the bottle, cap and label,” noted Horsefield. “Of course, easy changeovers reduce downtime. They also help us clear, clean and set up the line to run the next product correctly, which contributes to our high product quality.”
The integrated line begins with NJM’s Unisort 32 bottle unscrambler, followed by an Abox PD2XL desiccant pouch dispenser. Anchoring the line is a Cremer 622 tablet counter, which is currently equipped with three fill heads and fed by NJM’s TE10 bulk tablet elevator. Next is Mettler-Toledo’s Signature 300 metal detector, NJM’s beltorque® BT-ICL Lite capper, Enercon’s Super Seal Touch induction sealer, a buffer table and NJM’s Trotter 127 labeler. Following that is NJM’s belt transfer and a Leibinger Jet2 Neo inkjet coder. Capable of reaching speeds of up to 150 bottles per minute (bpm), depending on the fill count, 21st Century averages about 100 bpm across their range of products.
“We like Cremer 622 tablet counters because they’re so accurate and flexible. They can handle every solid dose product we have, with quick and easy toolless changeovers, and always hit the right count. In fact, on our 12 packaging lines, we now have four Cremers, all installed within the past two years,” explained Contreras. “The Cremer 622 on our new line can be equipped with four fill heads, which is a space saver compared to counters that require two machines to accommodate more than two fill heads. At the moment, we have three fill heads on this counter – we can easily add the fourth one later, plug and play, if needed. We’ve got a bulk product elevator that feeds this counter, which means one less person has to be dedicated to the line.”
NJM’s beltorque BT-ICL Lite cappers also help maximize product quality and production versatility at 21st Century. Unlike traditional cappers that use discs or spindles that can skew and scuff caps, beltorque features two pairs of belts that gently rotate and tighten caps by synchronizing the speed of the containers with the rotating speed of the closures. “We like beltorque cappers because they don’t damage our caps and the precision of the cap placement and torque lead to accurate capping and better induction sealing. Typically, a child resistant cap is the hardest for most cappers to apply, but beltorque makes it easy,” said Horsefield. “Right after we installed our second beltorque, we ordered four more of them for other packaging lines.”
21st Century selected NJM’s Trotter 127 labeler for their new integrated line based on their positive experiences with their older Trotter labelers. This adaptable pressure sensitive labeler can apply wraparound, front-and-back and 3-, 4- and 5-panel labels to round, square, rectangular and oval bottles. “Applying a three-panel wraparound label along with a back label to a rectangular bottle can be difficult, especially at the speeds we run – most manufacturers would shy away from that. Our success with this challenging application is pretty incredible,” noted Horsefield.
“We like working with NJM because of their industry expertise as well as their best-in-class technology and world-class service,” concluded Contreras. “They listen to our objectives and understand our challenges, and then they design the ideal integrated solution for us. We know the equipment will be robust and the line will perform as expected. The NJM team always stands behind the promises they make.”
NJM is a single-source provider of automated packaging machinery for the pharmaceutical, nutraceutical, biopharmaceutical, and personal care industries. Established over 100 years ago, NJM is both a manufacturer of select equipment and an integrator specialist for complete lines that require a high-level of market niche expertise, assisting customers from the earliest stages of project planning and line design through implementation and production. Their offerings include stand-alone solutions and turn-key integrated systems for liquid and solid dose products. NJM is a product brand of ProMach, a global leader in packaging line solutions. As part of the ProMach Pharma business line, NJM helps our customers protect their reputation and grow the trust of their consumers. ProMach is performance, and the proof is in every package. Learn more about NJM at www.NJMPackaging.com and more about ProMach at www.ProMachBuilt.com.
ProMach is a family of best-in-class packaging solution brands serving manufacturers of all sizes and geographies in the food, beverage, pharmaceutical, personal care and household and industrial goods industries. ProMach brands operate across the entire packaging spectrum: filling and capping, flexibles, pharma, product handling, labeling and coding and end of line. ProMach also provides Performance Services, including integrated solutions, design/build, engineering services and productivity software to optimize packaging line design and deliver maximum uptime.
ProMach designs, manufactures, integrates, and supports the most sophisticated and advanced packaging solutions in the global marketplace. Its diverse customer base, from Fortune 500 companies to smaller, privately held businesses worldwide, depends on reliable, flexible, technologically advanced equipment and integrated solutions. ProMach is headquartered near Cincinnati, Ohio, with manufacturing facilities and offices throughout the United States, Canada, Mexico, Brazil, Europe, United Arab Emirate and China. For more information about ProMach, visit www.ProMachBuilt.com.
About 21st Century HealthCare, Inc.
21st Century HealthCare, Inc., one of the largest international manufacturers of dietary supplements, has been making quality nutritional products for over 30 years. Headquartered in Tempe, Arizona, 21st Century has over 500 employees, offices in 7 strategic locations around the world and products sold in over 50 countries. 21st Century manufactures a wide range of dietary supplements under the 21st Century brand and several private label and contract manufacturing partner brands. Learn more about 21st Century HealthCare at www.21stcenturyvitamins.com.
Marla Labreche-Stallmann | Marketing Manager
+1 802 269 0025