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Pharma Liquid Automation

Robotic tray loading

Highest process safety in vial handling -
from manual to fully automatic operation

One of the world’s leading pharma producers of generics and biosimilars needed a smart solution to load and monitor trays of vials fully automatically. Previously, it had only been possible to load Akylux trays of vials manually and process steps in this connection usually involved substantial risks and manpower. The customer obviously assigned high priority to the safe automated handling of vials for high-quality pharmaceuticals. After the loading process, the trays of vials are first put in quarantine before being processed further.

Main focus was placed on process safety, gentle handling of product, protection against mix-ups and automatic in-process control. In times where prices are regulated in the pharmaceutical industry high economy efficiency was a relevant aspect and the low space available in the line installation was yet another challenge.

PEWO-flex

Robotic Tray Loader

Protection against mix-ups with non-labeled products
Controlling mix-ups with non-labeled vials had to be implemented by marking a data matrix code on the lids with invisible ink. Incorrectly marked vials needed to be detected and rejected reliably by a camera system. Among other things, this valid process prevents potential product mix-ups which is vital when products are not labeled. A fully automatic in-process control was also implemented.

Quick project implementation and qualification
The project involving three machine units was realized within a period of only 8 months. Following a successful qualification phase based on the GMP guideline of the EU, annexes 11, 15, and ICH Q9, the three ordered units were put into a three-shift production. pester pac automation’s robotic tray loading solution for the automation of vial handling provided the customer with a customized concept which completely met all specified requirements.