Assembly Platform for On-Body-Drug-Delivery-Systems (OBDS)

Challenges

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.

Our Solution

We developed a modular assembly platform based on a B&R linear transport system. The modular architecture allows individual process modules to be docked or undocked quickly, including component handling, cartridge insertion, closing processes, and functional inspections. The transport and gripping systems were designed to support different product variants without structural modifications. By separating critical process steps into an integrated laminar-flow area, product quality is maintained even when handling sensitive components. All formats and process parameters are managed clearly within the control software, ensuring fast, reproducible, and safe changeovers.

Special Features

The platform is fully modular and can be used for different OBDS variants. Individual functional units can be exchanged or added within minutes. The modular core is suitable for early clinical phases as well as later production volumes, giving the customer a long-term scalable solution. The B&R system architecture keeps the line open for extensions such as serialization, additional inspection modules, or upgrades to higher performance classes.

Processes

  • Assembly OBDS

    Assembly OBDS

    The platform has a fully modular design. Modules can be docked or undocked within minutes and can be customized. The range of functions extends from labeling and marking to inserting the active ingredient, pressing the lid, and serialization. Depalletizing and palletizing stations can be integrated at the beginning and end of the line. The system supports laminar flow applications and is suitable for small series in clinical trials and launch sites as well as for high-volume production environments. The central machine core can be used with different modules for different formats.2

  • Assembly of Syringe / Auto-Injector

    Assembly of Syringe / Auto-Injector

    Our assembly platform for on-body drug delivery systems is based on a stable and validation-friendly B&R system architecture. The entire system is completely modular. Individual process modules can be docked or undocked within minutes and can be individually designed for the respective application.

    The modules' range of functions extends from labeling and marking to inserting the active ingredient, pressing the lid, and serialization. In addition, depalletizing and palletizing stations can be integrated at the beginning and end of the line. A laminar flow concept is available for sensitive products and can be integrated into the platform.

    The system is suitable for small quantities in clinical trials and launch sites as well as for medium and large production volumes. The central machine core can be combined with different modules so that various product formats and variants can be realized within the same platform.

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