Enhancing Efficiency:
Control Software for Vial Filling and Packaging Automation

Industry

Life Sciences

Scope

Design / Implementation / Commissioning

Timeframe

3 months

  • 2

    machines

  • 12

    weeks of development & commissioning

  • up to 150

    vials / min

01

CLIENT

Producer of aseptic fill-finish packaging machinery dedicated to the pharmaceutical and associated sectors.

02

BUSINESS NEED

Our client needs an experienced external vendor for long-term cooperation - to speed up machine delivery and keep the quality. Provide control software for new machines for filling, sealing, labeling and packaging, based on Client’s standards and requirements.

03

CHALLENGE

To help our client achieve its goals, we faced the following challenges:

  1. Complies to Pharma/GMP requirements

    Complies to Pharma/GMP requirements

  2. Short deadline for the delivery that required to program the machine at the customer's site.

    Short deadline for the delivery that required to program the machine at the customer's site.

  3. Distributed know-how between German and US sites

    Distributed know-how between German and US sites

  4. In-line product control

    In-line product control

  5. Achieving high speed of 150 vials a minute,

    Achieving high speed of 150 vials a minute

  6. Programming and commissioning of filling and packaging machines (~30 servo-drives, inline control, vision system, etc.)

    Programming and commissioning of filling and packaging machines (~30 servo-drives, inline control, vision system, etc.)

A 5 by 6 grid of empty vials between two boxes

04

SOLUTION

A comprehensive suite of tailored solutions was developed to address the unique needs of our clients, including

  • Development of dedicated control application addressing specific needs of complex mechanical systems - SCARA type movement using two rotary Kinetix Axes, synchronization of all drives to ensure performance, at client’s site.
  • In-line quality control using Cognex Vision System, particle monitoring
  • Leading commissioning process ended with FAT and support during/after SAT
  • Full service included delivering of PLC, HMI and reports
  • Thanks to remote preparation and later remote support shorter time needed on-side (lower costs)
Rafał Cieślak

I am delighted that our engineering team, thanks to their knowledge and experience, could build these machines with our client. Not only because it brings a lot of fun, but also because it makes medicines (thanks to speed-up packaging) more available worldwide.

Rafał Cieślak

Head of Industrial Systems Engineering

Technology used

Allen Bradley PLC Rockwell FactoryTalk MS SQL XL Reporter Pilz Safety System Cognex vision system Kinetix Motion Control

05

OUTCOME

This advanced initiative not only ensured the timely delivery of products but also contributed to optimizing resources at the client's end through the effective engagement of external experts

  • The delivery time was expedited, and the Factory Acceptance Tests (FAT) were successfully conducted
  • Two machines were sent to the client on schedule, meeting all specified requirements
  • Collaboration with external engineers (human resources were released on the client's side)

  • 2

    machines

  • 12

    weeks of development & commissioning

  • up to 150

    vials / min

How can we help you?

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