The Challenge
F. Hoffmann La Roche faced the challenge of modernizing an existing semi-automatic production with cold glue technology. The critical scenario was a limited output of only 1 box per minute, which represented a bottleneck for the required small-batch production.
- Productivity Gap: Manual handling prevented scaling to the target of 8 boxes per minute (800% increase)
- Changeover Inefficiency: Long downtimes during format changes blocked line flexibility
- Safety Risks: The transition from cold glue to hotmelt technology required a new safety concept to protect operators from thermal hazards (160°C to 170°C operating temperature)
- Compliance Requirements: Ensuring a dimensionally stable, glued box while maintaining high variance of reference parts
- Format Diversity: Processing of folding carton blanks (from 170mm x 186mm to 329mm x 289mm) and web blanks (from 173mm x 50mm to 379mm x 117mm) in one system
The requirements were demanding: A solution for small-batch production had to be flexible enough to handle over 20 different format variants, while being GMP-compliant and fully validatable.
Our Solution
Pharmabotix implemented a fully automatic top-loading erector featuring a modular gripper and folding system:
System Architecture & Components:
- Precision Handling: Use of X-Z handling systems for cartons and webs, combined with decentralized vacuum generation via ejectors
- Drive Technology: Integration of Jenny Science linear axes for highly dynamic movements and Siemens S210 axis controllers
- Hotmelt Integration: Use of a Robatech gluing device with automated glue nozzles that set precise application points during motion
- HMI & Control: A 22″ touch panel in a swivel arm serves as central interface, controlled via Siemens TIA Portal
Technology Highlights:
- Quick-Changeover Concept: Through part-specific change parts (magazines, grippers), changeover time was reduced to under 3 minutes
- Safety Architecture: Separating protective equipment made of safety glass with safety-relevant interlocks and hotmelt temperature monitoring
- Validation: System design according to GMP requirements with central access management via Siemens UMC for connection to customer domain
- Compact Autonomy: Magazines for at least 15 minutes or 100 pieces of uninterrupted production
Data Integrity & Flexibility:
- Password-protected parameter management (PM-CONTROL) for up to 200 parameter sets with versioning
- Validated processing of over 20 different reference part combinations (carton & web)
- Complete encapsulation of hotmelt process and emergency stop category 1 for maximum personnel protection
Project Gallery
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