Last April 9, the local Fox News affiliate visited EG Industries’ Rochester – Emerson molding plant to do a telecast live on how Karma Wellness Water is made and the plant’s significant part in making it a very successful product. Starting at 6 o’clock in the morning, there were 4 segments broadcasted directly from all around the plant floor where the product is made.
For the past 7 years, EG Rochester – Emerson has played a major role in both part and process design, including even enabling several customer patents. The cap of the bottle is the key to making the packaging of Karma Wellness Water unique. To make the working part of the system, the base and the cup are molded in 2 Sumitomo machines in one half of the cleanroom. The entire process is synchronized to automation in line (much like the syringes made at the plant) where the cup is filled with nutritional powder. This powder gets mixed with spring water when the cap is pushed by the consumer immediately prior to drinking.
“The base, where most of the unique molding design and technology exists, is spin-welded to the cup/powder to completely seal the functional cap,” explained Alan Gross, EG Rochester – Emerson plant manager. “This operation takes place in the second half of the cleanroom using a four-up indexing rotary table. From there, the caps undergo another four steps alongside the cleanroom to slit tamper evident bands, embed date codes, and add labels before they’re packed into shipping boxes as our finished product. The caps are then sent to a bottler that attaches them to bottles of spring water. Lastly, product
labels are added to the bottles prior to distribution,” he added further.
Karma Wellness Water’s value proposition is that the sugar-substituted powder in the cap is introduced into the water at the time of consumption. This ensures the highest possible potency of the vitamins and nutrients in the product compared to premixed drinks that could sit on warehouse or store shelf for too long. Most ingredients in supplements and majority of vitamins lose potency over time especially under certain conditions. For example, if the product is stored away from heat, light, and humidity, supplements may last about 2 years from the date of manufacture. After that, concentrations indicated on the packaging begin to fall below 100%. Probiotics– live bacteria and yeasts that are good for your health, especially your digestive system– are more fragile and have a window of only about a year.
This explains why vitamin-enriched drink labels have a “use by” or “best by” date. These dates indicate the time period within which the product will be most effective and offer the most nutrients. If you drink vitamin water after their “use by” or “best by” date, you probably won’t get the same level of vitamins as you would from a fresher bottle. The powder in the caps of Karma Wellness Water comes in 12 varieties depending on the effect desired by the consumer. There are vitamin/mineral varieties, energy drinks, and probiotic versions. The effect is everything from “sharper thinking,” “healthy hydration,” and “fitness acceleration” to “higher energy,” “improved digestion,” and more.
The live telecast highlights how the collaboration of Rochester-based Karma Wellness Water, EG Rochester, and a product label vendor is making a great product successful.