Medical Products Assembly & Packaging - Clamshell Loading and Labeling
DMW Automation engineers and staff personnel designed a custom automated packaging line that solved a complex production handling problem while improving production efficiency and reducing costs.
Overview
- Location: Southwest
- Industry: Medical
- Products/Services: Injectable Drug Tray
- Primary SIC Code:
- Annual Sales: $500 million to $1 billion
- Technology: Indexing
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| Clamshell final inspection and closing. |
Situation
A major pharmaceutical manufacturer approached DMW Automation to develop a secondary packaging line for a new vacuum-formed clamshell tray they were developing. The unique challenge of this project was to handle sterile pre-packaged syringes without breaking the seal and insert a vial and a patient information pamphlet into the clamshell alongside each syringe.
The customer also requested that we combine our packaging automation with two Weiler Labeling Systems pressure sensitive labelers, providing them with a complete turnkey solution.
Action
DMW Automation personnel met with the customer to evaluate and examine the components of the new clamshell assembly and review the requirements of the packaging line.
Our engineers designed a custom solution to handle all of the production components. We first developed a prototype to demonstrate that the vial handling system selected to load the vials into the clamshells would not scratch or damage the vials.
Our solution used a combination of in-line and rotary Indexing systems. We loaded the clamshells 2 at a time onto a cleated transport conveyor and used a Scara 4-axis robot to place the labelled vials into the clamshells after they had been rotated 90 degrees by a feed screw assembly.
The equipment then placed the sterile pre-packaged syringes and patient information pamphlets into one of two rotary indexing dials used to transport them above the clamshells, before they were pushed into the clamshells. The syringes were manually fed onto a conveyor and automatically transferred into the rotary dials. The pamphlets were supplied in pre-packaged magazines and automatically placed into the rotary dial next to the syringes. We used a vision system to verify that a vial, syringe, and pamphlet were properly inserted into each clamshell.
Our equipment mechanically closed and ultrasonically sealed the clamshells and then transferred them to a second labeler to apply a booklet top label and a side label.
After fabrication and assembly, we conducted Factory Acceptance Testing (FAT) with the customer present and received their approval to ship the equipment. We shipped and installed the equipment on site and integrated it with the two Weiler Labeling Systems labelers.
Results
Our automated solution resulted in a fully integrated packaging line that reduced labor and production costs, eliminated quality issues by inspecting each clamshell prior to closing and labeling, and has been in operation for over 5 years.
For more information about DMW Automation’s custom automation equipment and systems services, please call us at 847-437-0665 or email us at sales@dmwautomation.com.
