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.
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