Transforming Pharmaceutical Carton Kitting with Robotics
Driving Precision, Speed, and Flexibility in Pharmaceutical Packaging
Introduction
In the high-stakes world of pharmaceutical manufacturing, packaging operations must deliver more than just output — they must meet stringent quality standards, ensure product integrity, and adapt rapidly to shifting demands. Carton kitting, a critical node in this chain, is often challenged by complexity, space constraints, and the need for speed without sacrificing precision.
A leading North American pharmaceutical company partnered with Catalyx to overcome these challenges and reimagine its carton kitting process through intelligent automation.
Context
The client faced a multifaceted operational problem:
- Complex product mix requiring rapid, seamless changeovers
- Tight production footprint demanding space-conscious automation
- High throughput and minimal operator intervention expectations
- Need for consistent quality assurance across packaging lines
- Compatibility with varied carton formats and insert requirements
To stay ahead in a competitive, regulated market, the client needed a transformative solution — not just an upgrade.
Our Solution
Catalyx engineered a purpose-built Robotic Kitting Module designed to optimize every aspect of the kitting workflow. The system integrates two high-precision Brooks Automation robots tasked with picking products from standardized trays and placing them into pre-formed cartons with exceptional accuracy.
Key Innovations:
- Compact Footprint: Air-driven tray drawers and conveyor systems maximize efficiency within minimal space
- Vision-Guided Robotics: Ensures accurate pick-and-place operations, minimizing human error
- Smart Verification: Built-in barcode and label checks enforce quality standards at each step
- Tool-Free Adaptability: Rapid configuration for different SKUs without the need for mechanical change parts
- Operator-Centric Design: Collaborative robotics with advanced safety features including light curtains, scanners, and access sensors
Whether deployed as a standalone system or integrated into broader packaging lines (e.g., serialization, carton forming), the module delivers unmatched flexibility and performance.
Results
The impact of the solution was both immediate and measurable:
- Zero Type 1 Errors
- Type 2 Error Rate < 2%
- 4 Cartons per Minute Throughput
- Supports 4+ Unique Kitting Workflows
- Universal Tray Design Across All SKUs
- Ultra-Fast Product Changeover Times
This high-performance system enabled consistent, high-volume output without compromising precision — even in a fast-paced production environment.
Conclusion
The Catalyx Robotic Kitting Module delivered a step-change in how the client approaches packaging. By combining advanced robotics, thoughtful design, and flexible engineering, the solution didn't just solve immediate challenges — it positioned the company for long-term success in a competitive and quality-driven industry.
This is automation at its best: scalable, smart, and built for the future.