Turnkey solution for combi kits
- A complete line from a single source
- Efficient supply and loading of various individual components
- Precise separation and accurate orientation of components
- Labelling
Requirements
Checking individual components and assembling combi kits
Focusing on efficiency and product safety:
An Italian pharmaceutical company has fully automated its packaging processes which were previously carried out manually with the aid of a turnkey solution and packaging line from Schubert-Pharma.
The line packs combination kits consisting of several individual components along with a contrast agent for ultrasound examinations. Over and above precise separation and accurate component orientation, the task also requires the integration of a
high-level communication system for serialisation of the products.
With the turnkey solution provided by Schubert-Pharma, the company was given a complete line from a single source. This has increased the pharmaceutical company’s capacity, enabling it to reduce wage costs while safeguarding its validated processes.
Solution
An efficient complete line from a single source
The fully automated packing process consists of three high-level processes: tray loading, labelling and cartoning into multiboxes. Gentle product handling is guaranteed by the individual robotic tools which precisely position the components in the trays and hold them in place.
The integrated high-level communication system ensures traceability and avoids batches being mixed up. Barcode scanners and cameras check that the data on the different product labels is correct before loading them into clamshell trays.
Schubert-Pharma has also efficiently integrated the infeed of individual components into the machine design as part of the turnkey solution.
I was excited about the machine from the start. We are anticipating rising production figures in the future. I’m already looking forward to seeing how our machine, which we refer to as the Mustang, will grow our production outputs.
Client’s Site Manager
Technical Details
Flexible automation for efficient processes
At the start of the process, clamshell trays are removed from the magazine, destacked and placed onto the Transmodul. Leaflets are also taken from the same magazine with a time offset and inserted into the trays – combining both components in one magazine saves space. In the next step, a pick-and-place robot places the first component of the combo kit – a plunger rod – into the tray. Transfer systems are then separated and positioned by an F4 robot in front of a camera to check the printed data. If the label data meets the specifications, the part is placed into the clamshell tray.
In the following module, a rotary table feeds vials containing the freeze-dried contrast agent into the system. An F4 robot places the vials onto a rotating station for camera inspection, where the variable label data is read and verified. If the data matches the current production batch, the vial is loaded into the tray. The next component – a prefilled syringe – is also only placed in the tray after successful verification.
A stand-alone labelling unit applies up to three labels after the clamshell tray has been filled and closed. The subsequent cartoning process begins by destacking the blanks and erecting the cartons. An F4 robot groups the incoming labelled trays and transfers them to the loading station. After insertion into the carton, a label is applied and the carton is sealed.
- Turnkey solution: Loading, labelling and cartoning of clamshell trays
- Transmodul in use
- Cartoning: 5 or 10 combo kits per carton
- Up to 50 combo kits per minute
