Application Note

The Benefits of Robotics In Pharmaceutical Packaging (FAQs)

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Q: Does robotic packaging equipment have particular advantages for pharmaceutical packaging? If so, what are they?

A: In many instances robotics are utilized to automate an existing manual process such as loading cartoners, horizontal form-fill-seal machines, or blister machines. In these cases, the advantages include increased speed, efficiency and an increase to overall equipment effectiveness (OEE). Other advantages may lead to reduced cost, reduced injury and eliminating re-work.

Robots are extremely accurate and repeatable. They operate 24/7 and, with options like vision and line tracking, can verify placement of product and track movement of continuous motion machines to keep up with production speeds.

Q: How do robots reduce contamination during pharmaceutical packaging?

A: Robotic packaging processes offer much greater flexibility compared to manual or non-robotic automated processes. The key to this flexibility lies in the end effector and the programming of robotic packaging equipment. End effecters designed with “quick release” connections experience a very fast changeover of less than two minutes in most cases. And increasingly sophisticated robotic controls can be programmed for different packaging applications with relative ease. These facts allow a single robot to handle multiple SKUs with little more than a new end effecter and programming. By contrast, application-specific hard automation, equipment designed to handle one type of product in a single application, becomes obsolete or requires expensive retooling when a manufacturer wants to run a new product on an existing packaging line.

A: Robotic cells typically offer a very small foot print compared to other types of packaging equipment. At the same time, these cells offer a generous work envelope, allowing the installed equipment to handle multiple packaging lines. A typical robotic loading, assembly, or collating system uses a foot print less than 3' x 3'. Even a dual cell palletizer, typically a larger robotic packaging machine, only occupies less than 12' x 10' of floor space.

In addition to the small foot print, robotic packaging lines can save space by using a single robotic cell for multiple functions, eliminating the need for additional equipment. For example, a robotic case packing and palletizing cell can be created that both loads product into cases but also places the filled case on a pallet, reducing the equipment and space required. Robots can be used to load multiple machine infeeds as well, allowing one robot to feed several lines, rather than requiring a feeder for each packaging line.