A leading pharmaceutical manufacturer of cleaning agents for eye lenses was facing significant challenges with product contamination in their new packaging line.

As a critical player in sterile medication production, ensuring a contamination-free process was not just a requirement but a mandate.

Read on to discover how automating bottle feeding and unscrambling helped reduce contamination risks and improve efficiency.
BACKGROUND
The client recognized that while their filling machines were well-protected, the upstream equipment handling empty bottles was a vulnerable point. Dust, particles, and even human contact posed a contamination risk that could compromise their entire production avoiding being certified to launch the product.
PAIN POINTS
  1. High Contamination Risk from Human Contact. Despite strict protocols, human intervention in feeding and handling empty bottles posed a significant risk. The need for manual operations in the line increased the potential for contamination, jeopardizing the final product.
  2. Limitations of Existing Unscrambling Systems. The client's existing bottle unscrambling equipment relied on turning tables which increased manual handling. These systems couldn't keep up with the production speed requirements and it was difficult to avoid contamination while increasing operational costs.
  3. Complex Certification Process. Customer wanted to avoid the hassle of having to repeat the certification process of the line due to adding new equipment.
SOLUTION

POSIMAT partnered with the client to implement a tailored solution designed to address these challenges:

Automated Feeding and Unscrambling: POSIMAT provided fully automated bottle unscrambler and hopper to feed the bottles, reducing the need for manual handling. This automation significantly minimized the risk of human contamination, creating a cleaner environment and enhancing operational efficiency. Operators simply place the closed bag with sterilized bottles onto the feeding system and the rest is automated (opening of bag and feeding of the line needs no human interaction).

Mechanical System with No Compressed Air: The POSIMAT unscramblers operate using mechanical systems that eliminate the need for compressed air, a critical improvement as air systems were previously a prohibited contamination source in the client's environment.

Easy Sanitization and Maintenance: The POSIMAT equipment can be disassembled easily, allowing operators to clean all contact parts thoroughly. The use of materials compatible with disinfectants ensured that all sanitization protocols could be met without compromise. Maintenance is virtually zero.

Fully automated bottle feeding hopper designed to supply a POSIMAT bottle unscrambler for efficient empty bottle handling in a pharmaceutical filling line.
Fully automated bottle feeding hopper designed to supply a POSIMAT bottle unscrambler for efficient empty bottle handling in a pharmaceutical filling line.
RESULTS

With POSIMAT's solution, the client achieved:

Reduced Contamination Risk: The fully automated and mechanically operated unscrambling system drastically cuts down contamination risks from human contact and environmental particles, ensuring a cleaner, safer packaging process.

Enhanced Flexibility and Efficiency: The multi-format capability of POSIMAT unscramblers allowed quick, tool-free changeovers, enabling the client to easily switch between different bottle types and future-proofing their investment for new formats. The systems operated at a low noise level of 80 dB(A) and handled up to 220 bottles per minute, meeting the client's high-speed production demands.

Front view of a POSIMAT bottle unscrambler for automated empty bottle handling in a pharmaceutical filling line.
Rear view of a POSIMAT bottle unscrambler for automated empty bottle handling in a pharmaceutical filling line.
CONCLUSION
By partnering with POSIMAT, the pharmaceutical company successfully transformed its packaging line, addressing critical contamination concerns and achieving greater operational efficiency. POSIMAT’s tailored approach and advanced unscrambling solutions provided the client with the reliability and flexibility needed to maintain the highest standards of quality and safety in their production processes.