Case Study: Combo packs/kits

To support end-user weight loss, up to 100 combo packs or kits are compiled and packaged per minute.

To this end, the following process steps are carried out:

  • Plastic bottom sections are depalletized and separated
  • The inner trays are separated and placed in the bottom sections
  • The tablet doses, delivered in bulk, are separated
  • The tablet dose and a coupon are placed in the inner tray
  • The online fed tablet bottles are grouped
  • The bottles are aligned as per label rotation position and inserted into the tray cavity
  • Bundled user information leaflets are gathered and inserted into the tray
  • A completeness check is run using an image processing system
  • Depalletizing, separating and placing covers on the bottom section
  • Applying base and lid labels printed with batch data
  • Verification of label printing and label position using image processing
  • The finished trays are packed in shrink-wrap film
  • The trays are grouped and placed in an upright folding box
  • The folding boxes are sealed and labeled
  • The folding boxes are palletized and stretch-wrapped

All control functions and data acquisition systems were combined to enable  continuous data storage and download of the new batch data. Here, CFR Part.11 requirements were taken into account.

Before start-up, the system underwent a comprehensive validation.


Case Study: Inhalers

A system supplied to the American market takes fully assembled inhalers and leads them along a line with a storage capacity of over 10 minutes, before they are labeled with a printed-order-specific data label.

Downstream, the inhalers are then…

  • Packaged in an airtight, labeled tube bag
  • Slid into an upright side-load folding carton with an information leaflet
  • Sealed in folding cartons, grouped and placed in layers in erect shipping boxes
  • The shipping cartons are then sealed, labeled cross-corner and finally palletized

 The total system, including the installed line management system, undergoes risk-based planning and validation.


Other applications: Packaging single-unit batches for Hoffmann-La Roche

One of the greatest challenges for a manufacturer in the pharmaceutical sector is absolute safety in the packaging of clinical trials – a process which has always been done manually due to its difficult tracking.

For the first time ever, Schubert-Pharma developed fully automated implementation for Hoffmann-La Roche in Switzerland. Schubert-Pharma configured a highly flexible cartoning machine for blister packs, syringes or vials.

The highlight of the machine is the possible product tracking with management of all data – from trial information specifications, to individual product and patient information through to clinic assignments. Together with Hoffmann-La Roche, Schubert-Pharma configured the connection to a primary or parent data system.

 The solution implemented for packaging the trials consists of the following steps and functions:

  • Automatic product feed into the machine
  • Identifying individual products with trial data
  • Erecting top-load boxes
  • Marking the boxes with serialized trial data
  • Loading the individual boxes
  • Closing the boxes
  • Erecting the outer packaging
  • Grouping and loading the patient kits in the outer packaging
  • Labeling the outer packages with readback and management of printed data
  • Preparing and archiving the production or trial data
  • Submitting the outer packages and data to downstream logistics


Other applications: Wallet packaging

The wallet market is a distinctively high-quality niche market. All the more reason for one of the leading manufacturers of hormonal preparations to package its products on Schubert-Pharma systems.

With 240 blister packs per minute, the planned and implemented systems are highly efficient and deliver exceptional performance.

For the client, Schubert-Pharma engineered the high-performance wallet sleever with a blister buffer and an integrated foil wrapping machine. The system’s dynamic buffer allows a buffer time of up to 10 minutes of production time. As a part of the project Schubert-Pharma conducted an engineering study on line efficiency together with its customer.

The packaging solution for up to 240 blister packs per minute consists of the following steps and functions:

  •  Grouping and positioning the blister packs for the wallet process
  • An integrated dynamic buffer
  • Positioning and gluing the wallet sleeves
  • Inserting the blister packs into the wallet cards
  • Folding processes to close the wallets
  • Laser coding of the individual wallets
  • Adding the information leaflet
  • Grouping product into salesunits
  • Film wrapping of the sales units
  • Vignetting the packs with readback and data management
  • Forwarding product to downstream packaging into shipper cases