Production Line for Assembly, Labeling, Inspection, and Packaging

Challenges

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.

Our Solution

We developed a modular FlexLine based on a B&R linear transport system. Multiple assembly robots perform force- and position-controlled joining processes for syringes and devices. A robot-assisted labeling system handles various label types and is monitored by integrated camera systems. A second robot line completes the products with booklets and places them precisely into toploader or sideloader cartons. All process steps are monitored by camera systems, and format changes can be carried out reproducibly.

Special Features

The FlexLine integrates assembly, labeling, product inspection, and packaging into one continuous automation concept. The B&R linear transport system enables flexible cycle sequences and variable process chains. Its modular architecture allows additional process stations, new formats, or further product families to be integrated with ease. The solution covers a wide range of pharmaceutical applications and is scalable for future requirements.

Processes

  • 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.

  • Labeling

    Labeling

    Our labeling solutions cover performance classes from manual loading to 60 and 150 pieces per minute and support round, flat, and elliptical products. The systems can be flexibly combined with palletizers and tray loaders.

  • Palettizer

    Palettizer

    Our palletizing platform is suitable for syringes, vials, pens, and many other products. It offers precise handling, high process stability, and flexible customization options.

Images & Media