products per minute

formats

Six blanks at a time pass through the erecting process in parallel across different sections of the line. “The result is twelve erected cartons standing on a single Transmodule,” explains project manager Luca Blümlein. Further downstream, the machine
folds twelve partitions at several stations, glues them into the erected cartons, places first vials, syringes and needles, then leaflets into the cartons, and finally closes them. To do this, an F2 robot first folds the partitions into the required shape using a folding
unit, then moves them over the gluing station. There, the partitions are glued and bonded into the erected cartons on the Transmodule. Meanwhile, syringes enter the process lying flat on an infeed chain. An F2 robot picks them up in a formation of 24 and places them on a table inside the machine, which spreads the syringes into two formations of 12. A second F2 robot then picks up one formation at a time from the table and loads the cartons on the Transmodule. Vials and needles reach the partition-fitted cartons through similar processes. Finally, robots place package inserts on top of the products before the machine closes, prints and labels the cartons. The finished cartons leave the line on an outfeed conveyor. A critical aspect: camera systems monitor all materials for correctness and completeness at every stage. This applies to material codes on the blanks as well as to the partitions and cartons, which the systems check for squareness among other criteria. Each infeed also has its own camera to verify that the correct vials, syringes and needles are being processed. Schubert additionally relies on what are known as challenge tests to thoroughly verify critical functions before every new batch. For these test runs – during which codes are blacked out or dummy products are introduced into the process, among other measures – Schubert programmed the machine specifically for this customer. The test mode can be called up at any time via the operator interface and run for both blanks and finished packages. The system logs all  results automatically in the batch report.

There is yet another feature that sets this machine apart – one that is an absolute must in the pharmaceutical sector: Schubert Pharma engineered the line so that products remain visible at all times and stay inside the machine, even if they tip over or roll
away. In keeping with the line clearance concept, the interior of the system is clad with sheet metal panels, eliminating any gaps or cavities where products could become lodged. This line, designed from the ground up for sustainable, flexible packaging, thus
delivers a high degree of production reliability – "a critical factor for vaccines that must be available without interruption," notes Blümlein. Bringing this high-performance line to fruition required Schubert Pharma and the manufacturer to overcome a number of challenges – from testing the infeed systems in Crailsheim to developing partitions that had to fit seamlessly into the existing cartons. The goal was a single, standardised carton that could accommodate different product combinations without any compromises compared to the previous format using thermoformed blisters. Working closely with the PCC and the manufacturer, Schubert Pharma homed in on the right partition design. "Direct communication and an iterative approach made all the difference," says Blümlein, describing the process. The PCC also made adjustments to the cartons themselves in collaboration with the customer to ensure the interior and exterior of the carton work in harmony. The result is not just a versatile end-to-end solution, but a genuine first for the
manufacturer. The system packages up to 270 products per minute across a wide range of combinations – with minimal changeover effort. Only one format – two vials without a needle and syringe – requires the customer to swap the filling tool. "Thanks to our proven technology, they save valuable time," Blümlein emphasises. Nothing now stands in the way of flexible vaccine packaging – and a reliable supply worldwide.