Individual machine solutions for your pharmaceutical production

Not every pharmaceutical application can be implemented efficiently with a standard solution. That’s why at Schubert we develop customized packaging machines that are precisely tailored to your requirements – from the integration of specific formats to special transport and handling needs.

Our modular top-loading systems provide the flexibility needed to implement even complex packaging processes safely, GMP-compliantly and efficiently. Together with you, we develop solutions that fit precisely with your line and product portfolio.

Different product blisters and various batches are fed into the Schubert transport system via a rotary magazine. At the machine infeed, the applied DataMatrix codes (DMC) are automatically checked.

The captured information is transferred to the customer’s control system via the Line Control System developed by HEITEC and from there distributed to all relevant components of the line. This ensures that laser, printing and camera systems as well as RFID read/write heads always have the correct data available.

A central principle here is 1/Batch processing: Each product is clearly assigned to a batch. This guarantees complete traceability, data security and a smooth production flow – even with varying products and batch sizes.

For efficient and process-reliable marking, labels are processed in parallel with the packaging process. From a continuous label roll, a four-lane label set with a total of eight individual labels is produced.

These labels are first cut, then printed with product-specific information and checked for accuracy and quality using a camera system. After successful verification, the labels are precisely folded before being fed into the main transport system and integrated into the subsequent packaging process.

For cartoning, Schubert developed special blanks that can be used in both top-load and side-load applications.

This dual design ensures that the blanks can be processed smoothly not only on Schubert machines but also on side-load machines at other production sites.

In this way, a standardized packaging solution is created that works across sites while providing maximum flexibility in production.

The patient ID card serves as a central data carrier in the pharmaceutical packaging process. The integrated RFID chip securely stores product-specific information – such as batch data or patient-specific details – and enables contactless reading.

In addition, laser marking on the patient ID card allows permanent labeling with further relevant data. This reliably links production and patient data, which is essential both for traceability and for patient safety.

The distribution center plays a key role in the organization and allocation of pharmaceutical products within the packaging line. Here it is defined which distribution center receives a specific number of products from a batch. In the Schubert solution, this is represented by five parallel product chains, each taking up and transporting cartons.

The special feature: the system is designed for precise tray filling. Up to 19 cartons per chain can be placed in one tray. Specially developed cassettes, arranged on two levels, serve as distribution centers. These cassettes also function as a buffer system, ensuring continuous packaging operations without downtime. Once a cassette is completely filled, it is automatically moved into the unloading position.

In Schubert’s packaging process, there are no classic rejections of entire product groups. Instead, the machine uses what is known as the “recovery cycle.” All components classified as good – such as carton blanks, label sets or patient ID cards – remain on the Transmodul. Only the defective or missing component is reproduced and added during a second pass.

The advantage of the recovery cycle: incomplete product or packaging groups are not immediately treated as waste but are passed through the machine again. This significantly reduces material consumption while increasing process reliability. Unlike conventional machines, where a single error leads to the rejection of all components that then need to be manually completed, the correction here takes place fully automatically and efficiently.