FEATURE Packaging
PRECISE PACKING OF PRE-FILLED SYRINGES
Tekpak Automation has been able to double throughput for a medtech firm packaging pre- filled syringes, while reducing labour, footprint and packaging logistics costs
W
hen a multinational biopharmaceutical manufacturer approached Tekpak Automation, the
initial requirement appeared straightforward: automate the closing of pre-made cartons containing pre-filled syringes. But with production demand increasing, limited cleanroom space and a challenging 12-14 month lead-time requirement, the project quickly evolved into something much more ambitious. Tekpak developed a fully automatic top-load cartoning system incorporating AI-enhanced machine vision, precision robotic handling and automated carton and insert forming. The result is a compact, highly integrated packaging solution that has more than doubled production capacity, increasing output from a maximum of 12 devices per minute to 25 single-device packs p/m (or 50 devices p/m in double packs). At the same time, the number of operators required on the line has been reduced from six to 1.5, while the customer has also brought carton forming in-house, reducing transport costs and packaging waste. Frankie Rose, Technical Sales Manager for
Tekpak Automation, said: “Existing operators have been relocated elsewhere within the business or upskilled to support the operation of the new automated line.” A longstanding Tekpak client since 2015, the customer’s original brief for this project – packaging pre-filled syringes for the global biopharmaceutical market – was deliberately narrow. Pre-made cartons were being shipped from mainland Europe to the company’s Irish facility, where they were manually inspected, loaded with the product and leaflet, and glue-closed. Initially, the customer simply wanted Tekpak to automate the carton-closing operation. As discussions progressed, the scope expanded. Rose added: “The conversation moved from closing the cartons, to loading them, then to forming the cartons themselves. Inserts were
24 October 2026 | Automation
subsequently brought into the automation project, too. What began as a carton-closing application therefore evolved into a fully automatic packaging system, integrating carton forming, complex insert handling, product inspection, robotic loading, leaflet insertion, carton closing and final verification.” One of the project’s biggest constraints was physical space. The existing production line incorporated serialisation equipment at its downstream end. Relocating this equipment was not a viable option, so the new packaging system therefore had to fit into the existing production environment without moving the serialisation equipment. This made footprint a critical design consideration from the outset. Tekpak’s modular approach to machine design enabled the system to be configured around the available space. The result was a compact automated system capable of delivering substantially greater production capacity, without requiring changes to the downstream serialisation process. Lead time was another major consideration.
Increasing order volumes meant that the manufacturer needed additional packaging capacity quickly, with a target project delivery timeframe of approximately 12-14 months. The modular design of Tekpak’s technology was again instrumental in meeting this requirement. Tekpak was able to develop the solution around a series of integrated modules, allowing the system to be engineered specifically to the customer’s requirements while maintaining the required project schedule.
“This combination of compact design, modular technology and application-specific engineering helped us deliver a solution that our competitors could not match within the customer’s required timeframe,” said Rose.
Automating the handling of the pre-filled syringes presented another challenge. The devices arrive on the conveyor with small variations in both position and orientation. This variability can make accurate robotic handling difficult. However, Tekpak addressed this using AI-enhanced machine vision.
“As each syringe enters the system, the vision technology identifies its position and orientation on the conveyor,” explained Rose. “This information is then used to synchronise the robot’s movement with the individual device. The robot can accurately pick each syringe regardless of its orientation on the incoming conveyor and place it correctly into the packaging process. This eliminates the need for operators to manually orientate the products before loading, while maintaining the speed and accuracy required for automated production.” At the heart of Tekpak’s solution is a fully automatic top-load cartoner comprising 19 stations. The carton itself is produced from a flat blank, allowing the customer to receive and store unformed cartons rather than importing pre-formed packaging. The inserts, however, presented an additional engineering challenge due to their complex geometry, effectively forming an almost negative profile of the pre-filled syringe. As a result, six stations within the machine are dedicated specifically to folding, gluing and placing the inserts.
Once the insert has been assembled and attached to the carton base, a combination of probe sensors and AI-enabled vision technology then verify the completed carton. Any item that fails the inspection is automatically rejected, while approved cartons continue through the process.
automationmagazine.co.uk
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