Case Packing, Aggregation and Palletizing for Pharmaceutical Production

Need

The customer needed to automate the end-of-line packaging in their HMLV flow (High Mix, Low Volume)

The machine needed to be able to manage frequent batch and format changes whilst keeping a high availability and be future-proof.

An important requirement was to ensure full traceability through aggregation of carton-to-box and box-to-pallet.

The solution had to meet the pharmaceutical industry's requirement of GMP validation as well as have a high availability with a short changeover time.

Solution

A neat, compact and completely automated end-of-line packaging cell with two ABB robots.

What the system does in an integrated solution:

Automatic box erection
Carton grouping
Carton packing
Labeling
Box sealing
Aggregation
Reject management

The first robot picks cartons from an incoming FlexLink-conveyor and packs them in a pattern in the shipping box with the assist of a collation table. The robot has an automatic tool changer to allow for quick and flexible management of multiple product formats.

The second robot handles the box erection, sealing, labeling, aggregation and palletizing. The system includes label inspection, integrated reject management, and automatic pallet stacking with a pre-defined pallet pattern.

A Systech-solution has been integrated for traceability and serializing. Cartons are aggregated in the box through a camera above the packing station and the completed box is subsequently aggregated to the pallet level via dedicated camera stations. The solution ensures full product traceability throughout the packaging workflow.

Result

A future-proof and flexible end-of-line packaging solution that automates the entire process from carton to finished pallet while minimizing the need for operators.

The solution meets the requirements for high availability, rapid format changes, and reliable product quality in an environment characterized by numerous product variants and small batch sizes.

The integration with Systech enables full aggregation and traceability from the individual carton to the shipping box and on to the pallet, thereby strengthening patient safety, regulatory compliance, and supply chain efficiency.

The result is a validated end-of-line packaging cell that combines robotic automation, serialization, aggregation, and palletizing into a compact and operator-friendly solution.