FEATURE Robotics
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Selective robot integration adds value in pharma manufacturing
Selective integration of industrial robots is a solution accelerator for automation specialists working in the pharmaceuticals sector, from drug manufacturing to pharmacy automation
P
harmaceutical manufacturing is intensively automated to meet practical and fi nancial targets. Throughput must be high and
errors low to ensure profi tability. Another advantage is that removing human interaction helps avoid contamination to ensure high quality and consumer safety. The sequence of processes and layout of the production line can be complex and the entire production facility can occupy a large fl oor space. This can be challenging to design and the resulting installation can be expensive to build using conventional, customised factory automation. A common approach is to introduce industrial robots to perform specifi c processes within the sequence – particularly where items need to be moved or positioned individually. In these situations, the system integrator can take advantage of the robot technology as a convenient and cost-eff ective ready-to-use solution. The integrator can program the robot by teaching or simulation, using graphical software. An off -the-shelf gripper, supplied by the robot maker or a third-party specialist, may be suitable for the task at hand, such as lifting or holding. Otherwise, a custom-designed end eff ector may be needed. Integrating robots selectively in this way yields a compact production line that can be delivered quickly and saves bringing up an application-specifi c design using conventional automation technologies. They are frequently used in places where conveyors and palletising are required. Typical tasks include handling and sorting pills, capsules, vials and other materials, as well as picking, placing and aligning items like bottles, cartons and trays. They are also used for fi lling and capping containers, placing tablets, capsules and vials into blister packs, attaching labels to containers, and packing fi nished products into boxes, ready for shipping. Robots are also suited to processes that involve mixing and dispensing ingredients for drug formulations. In addition, where items such as containers are brought to the factory fl oor in bulk packs as received from
16 September 2023 | Automation
Figure 1: Yamaha’s YK350TW
the supplier, a SCARA robot can pick items such as empty bottles individually from a pile. An intelligent sorter can enhance picking by randomly re-orientating the items between picks. The item can then be correctly placed and aligned.
Robots expand options Various types of robots can be used for the pick and place, sorting, packaging and assembly processes. SCARA-type machines are often chosen as they off er a combination of high speed and dexterity with long reach and large load-carrying capacity. Ceiling- mounted robots such as Yamaha’s YK-TW orbit-type SCARA series (Figure 1) enable a smaller footprint by picking and placing items in any location within the area beneath the robot. In addition, these robots have a lower height than alternatives such as delta robots. Camera integration, controlled using dedicated robot-vision instructions through the RCXiVY2+ controller, allows high-speed alignment and inspection of items such as bottle caps and labels. SCARA robots are also available in dust- and drip-proof and cleanroom-ready specifi cations (Figure 2), specially designed with IP65 protection rating and direct- driven moving parts to eliminate debris resulting from drivebelt wear. Such units are available with arm length from 180mm to 1000mm, and maximum payload from 1kg to 20kg, giving a large range for typical
Figure 2: Yamaha’s YK800XC
pharmaceutical production line. Compact, application-focused 2-axis, 3-axis and 4-axis pick-and-place robots such as Yamaha’s YP-X series provide another option for designers, bringing special attributes such as minimal width for use within tight space constraints. Automation companies can deliver extra value by integrating robot-based technologies at other places in their line, particularly for transporting items from one process to the next, usually done with custom conveyors designed and commissioned specifi cally for the task.
Pharmacy automation Robots are also changing perceptions of the pharmaceutical industry close to the point of care, in automated pharmacy systems that improve and accelerate dispensing of medicines for patients.
Pharmacy automation takes over the labourious mixing, measuring, counting and capping traditionally done by pharmacists. It can even fulfi l prescriptions when the pharmacy is closed. Pharmacists can thus spend more time counselling patients and delivering preventive services, such as health screening and vaccinations.
CONTACT:
Yamaha
www.yamaha-motor-robotics.eu
automationmagazine.co.uk
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