Project Overview
For this project, we took the lead as the primary engineering partners for a consumer packaged goods startup in the nootropics space.
We were responsible for delivering a turn-key solution to enable their business to grow from small-scale product and customer research to market entry at scale. This included responsibility for the mechanical, electrical, and software design as well as prototyping, design refinement and testing, and final commissioning and integration into the customer's operation.
As owners of TriSystem Solutions, we managed every facet. We evaluated the operating environment, identified key opportunities for improvement, and determined the relevant regulatory constraints to ensure compliance.
From there, we subdivided the project into core functional modules, generated preliminary designs, and moved forward into prototyping with the customer's approval. Each module was extensively tested, enabling data-driven design refinement
and paving the path forward toward final system integration. With the system completed, we supported integration into the customer's operation and enabled them to hit the key manufacturing objectives necessary for the successful scaling of their supply of product to market.
Following Our Process
Leveraging our experience across multiple domains, we subdivided this project into core functional modules, testing each extensively to ensure a data-driven path to final integration.
Research
We evaluated the customer's original processes, characterized the flow properties of their powdered product, and identified an effective path forward while maintaining regulatory compliance.
Examples of Solutions Delivered
Material Science & Analysis
To resolve powder flow and handling issues reported by the customer, we designed and conducted a series of tests to determine its Carr Index, Hausner Index, and static angle of repose. Armed with this data, we identified and recommended a suitable food grade glidant additive which successfully solved the customer’s problem without degrading other product properties.
Modular Hardware Design
To provide accurate buffering and metering of the incoming powder flow, we custom-designed a hopper and volumetric metering module which connects to the top of the machine with quick-release toggle latch clamps to allow easy removal for cleaning and hardware changeout, enabling the processing of different powder sub-types without risking cross-contamination.
Precision Thermal Control
To rapidly and reliably seal the ends of each of the product sachets, we developed an automatic reciprocating sealer which incorporates a pneumatic drive mechanism for precisely controlling the clamp force on-the-fly as production conditions vary. Thermal isolation for the sealing faces is provided by geometry which is CNC machined directly into the jaw carriers. The temperature at the sealing interface itself is tightly controlled via a fine-tuned PID control system implemented on the electronics we specifically engineered for this project.
Modular Hardware Design
Tying everything together is a purpose-built electronic control and data acquisition system integrated directly into the machine. This hosts a software utility which allows the customer to remotely monitor both the operating conditions and the production throughput of the machine at their convenience to ensure it is always meeting their production objectives
Output & Effect
By the conclusion of the project, we delivered a finished, purpose-built pouch manufacturing machine which had the following business impacts:
36.4X
Production Throughput Increase68%
Reduction In Cost of Goods Sold