Our case studies provide insight into implemented automation solutions from the pharma, medtech, and industrial sectors. Each system was engineered for specific requirements and demonstrates how we automate processes in a stable, flexible, and reliable way.
The examples can be filtered by application, technology, or industry. This gives you a direct view of how we solve complex tasks and which technologies we use to implement them.
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The system must process different autoinjector and tray formats on the same line. Fast and safe format changes, high process stability, and clear, traceable management of all product and tray formats were key requirements. The machines are designed for the following autoinjectors:
The system had to ensure a continuous product flow with high process stability within a very limited footprint. Variations in carton and box tolerances made automated handling more challenging and caused disruptions with conventional feeding concepts. At the same time, the system had to be GMP-compliant and fully integrated into the existing line control architecture.
Blisters were delivered in sealed inner boxes containing twelve units each, which were themselves packed in sealed shipping cartons of forty inner boxes. All blisters had to be removed, oriented, and placed with exact alignment onto the pockets of a conveyor indexing belt. The system required stable handling despite the multi-level packaging structure and the need for high throughput.
The system needed to reliably assemble a complete on-body drug delivery device including the cartridge. It required high variant flexibility, short changeover times, and a stable line flow despite multiple sensitive process steps. In addition, solvent-sensitive components had to be processed within a defined laminar-flow environment. From the outset, the line had to follow a modular architecture to allow future process modules to be added or replaced quickly.
The line needed to process different autoinjectors and multiple tray types while ensuring high process stability despite its design as a small-batch and laboratory solution. In addition, both rotary and non-rotary labels had to be applied, including booklet labels. For study batches, placebo and active-ingredient pens had to be indistinguishable after labeling. A product-specific serialization concept needed to be implemented with full flexibility. Format changes had to be fast, reproducible, and clearly guided.
The palletizer was designed in a U-shaped layout and needed to handle both de-stacking and stacking of trays while unloading syringes from each tray. The required tray exchange time was below 1.4 seconds. The system also needed to operate with high autonomy: six tray stacks on both infeed and outfeed sides, each containing ten trays, corresponding to approximately thirteen minutes of buffer time.
The system needed to assemble a plastic membrane into a bottle nipple without applying stress to the material, followed by an activation step via defined pressure. A documented inspection cycle for opening and closing pressure had to be performed. All process steps required precise control and traceability, including verification of membrane positioning.
The width of each barcode clip had to be measured before labeling. The label needed to be positioned with high precision (tolerance ±0.1 mm). Each label carried a unique identification number that had to be verified by a camera system. Non-conforming labels had to be reliably rejected through a validated software-controlled process.
The system had to process different device and syringe types as well as multiple tray formats. Tray dimensions ranged from very small (300 × 150 × 15 mm) to very large (605 × 405 × 80 mm), requiring a highly flexible transport and infeed concept. Stable alignment prior to unloading was essential to ensure reliable downstream handling.
Blister trays were delivered in shoe boxes with 20 layers, distributed across two levels with significant positional tolerances. The handling system needed to compensate for these tolerances through sensing and ensure stable picking and transfer to the downstream sealing process.
The system needed to assemble eight components in two different product variants, including the handling of a dimensionally unstable membrane. In addition, the pump performance had to be tested and calibrated within an integrated test station. The solution required stable feeding, precise assembly sequences, and reliable inline quality control.
The system needed to provide a fully flexible automation solution capable of assembling, labeling, inspecting, and packaging syringes, devices, and vials into different carton types. In addition, booklets had to be fed automatically and integrated into both toploader and sideloader cartons. The line required full format flexibility, the ability to combine multiple process steps, and clear traceability across all variants. Despite the wide range of tasks, the overall machine layout had to remain compact.
Calibrators had to be fed in two parallel lanes from trays. Any gaps occurring during infeed needed to be automatically closed. Depending on the carton size, calibrators had to be fed either standing or lying. The system required an autonomy time of twelve minutes and stable performance across varying product orientations.
The system needed to assemble thermal SMD fuses while monitoring all joining steps, laser-marking the housing, performing a soldering process, and completing an electrical end test (current and resistance measurement). All steps required high repeatability and stable inline quality control. The system also had to separate IO and NIO parts and package the approved fuses into blister tape.
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