A turnkey solution for combi-kits
Which horse stands for greater tenacity, adaptability, intelligence and spirit than the mustang? These are precisely the characteristics that an Italian pharmaceutical company sees in its new Schubert system: hence, its nickname - the Mustang.
After the client got in touch, Sales Account Manager Karin Kleinbach visited the client several times and a customized approach was drawn up. The entire project, from the customer request to the installation of the machine, took about two years. Previously, all the other secondary packaging processes, with the exception of the labelling of the primary products, syringes and vials, were done manually at the client's Swiss location.
Clear competitive advantages
Components form one unit
With the exception of the operators feeding the system with materials, the packaging process is now fully automated. It consists of three high-level processes: tray loading, labelling, and cartoning in multiboxes. The sealable trays are taken from the stack and positioned on the transmodule. Leaflets are taken from the same storage space and placed in the trays. This single-store combination saves space and is particularly beneficial given the fact that the client is short of space. In the next step, piston rods, which enter the system from a vibrating container, are added to the tray. An F4 Pick-and-Place robot takes the suspended piston rods from a star wheel. With a horizontal tilting motion, the robot sets the piston rods down. Next, a centrifugal sorter is used to separate out transfer systems and an F4 robot positions them in front of a camera to verify the product information on the labels. The transfer systems are only added to the tray if the information matches the pre-set data. In case of a mismatch or a reading error, the transfer systems are immediately rejected.
In the third step, a rotary plate feeds the vials with the freeze-dried contrast agent into the system. Here, an F4 robot places the vials on a turning station in front of a camera, which detects and verifies the variable data on the transparent label. If the data match the current production batch, the robot adds the vial to the tray. The next component for the tray, a syringe filled with WFI, is also only placed in the tray once the variable data on the label has been successfully read and confirmed as being correct. These syringes have been hung from a vibrating container and fed into a star wheel. As the syringes are placed precisely into the trays, the orientation of the finger flange plays a particularly important role. It is aligned parallel to the base and top of the tray. The clamshell is then closed and moved to the outfeed belt.
Looking to the futureThe new machine concept offers the pharmaceutical manufacturer a high degree of flexibility in the final packaging: Other combi-kit formats can be easily implemented without the need for any major changes. The site manager's summary was accordingly positive: "I was excited about the machine from the start. We are anticipating rising production figures in the future. I'm looking forward to seeing how our machine, which we call the Mustang, will grow. The work the Schubert-Pharma team did was impressive and innovative," he said, summarizing the positive collaboration with Schubert-Pharma.
Hall 3.1, booth G47