Introduction

Efficient carton kitting is essential in the pharmaceutical industry to optimize production processes and maintain product quality. Our pharmaceutical client encountered several challenges in their carton kitting processes. Firstly, they needed to simplify carton kitting for various product styles within a restricted footprint. Additionally, the system had to maintain high throughput rates and walkaway times to meet production demands. Furthermore, accommodating different carton sizes and efficiently handling product loading, leaflet insertion, and carton verification were critical requirements for the project’s success.

Solution:

Catalyx developed a Robotic Kitting Module equipped with two Brooks Automation Precise Robots to handle the picking and placing of products from loaded trays into pre-formed cartons. The system incorporates air-driven drawers for tray loading and infeed/outfeed conveyors for carton transfer. Catalyx SmartFactory Machine Vision guidance technology ensures precise picking and placement, while barcode verification and label presence checks bolster quality control measures. The module’s adaptability allows it to accommodate various product styles without requiring change parts, and it features tool-changing capabilities for the robots and interchangeable leaflet systems.

To prioritize operator safety, Catalyx implemented collaborative robots and robust safety architecture. Safety scanners and light curtains prevent access to the machine during operation, immediately halting and evacuating air in case of intrusion. Door sensors further restrict access to the lower section of the system during operation, ensuring maintenance procedures are conducted safely.

The Robotic Kitting Module offers versatile integration options, functioning as a standalone system or seamlessly integrating into larger processes. For example, it can be integrated with carton formers or serialization lines, further automating production processes and enhancing overall efficiency and productivity.

Customer Outcome

The implementation of Catalyx’s Robotic Kitting Module revolutionized carton kitting processes for our customer, delivering precision, flexibility, safety, and efficiency. By harnessing cutting-edge technologies and seamless integration capabilities, the solution empowered our customer to achieve transformative outcomes, driving automation advancements and ensuring success in the industry.