The available layout offered limited space, while the line required high process stability at a continuous ramp-up. The different box variants showed real-world tolerances that caused disturbances with conventional mechanical feeders. The system also needed to be easy to clean, fully GMP-compliant, and seamlessly integrated into the existing 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.
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