The modular architecture of our ESSERT MicroFactory is based on our ADVANCED Robotic Workstation modules and the ability to combine them flexibly according to your requirements.
The scalable, highly flexible production line is specially designed to meet the challenges of high mix / low volume production and to increase your efficiency.
Choose from a variety of predefined, standardized process modules or define your own production processes.
Independent commissioning
Each process module can be independently commissioned, fully tested and quickly integrated.
Plug & Produce
Customize the initial configuration of your MicroFactory at any time. Add new process modules or exchange current modules as required.
Manual workstation
Integrate manual processes whenever you choose, e.g. for manual inspection or specific processing steps.
Service friendly
The high level of standardization enables us to provide you with excellent service.
Scalable & reconfigurable
The modular system can be easily extended and allows a wide range of new and future products to be mapped with minimal effort.
Define your processes for the MicroFactory modules
Process modules
Process modules
All process modules of our standardized automation platform can be effortlessly and effectively implemented, with the help of our Plug&Produce interfaces
The ESSERT MicroFactory combines the capabilities of several advanced robotic workstations, each of which can be customized to perform a specific manufacturing task. One process – one module.
Each robotic workstation can be tailored to meet the specific needs of each production stage and quickly adjusted to accommodate changes in your manufacturing workflow.
The entire MicroFactory can be reconfigured, making it a scalable and flexible solution for automated production processes.
The result is very satisfying! We were able to save about 75% of the costs. Without this measure, we would have had to relocate or even lost the products.
Dirk Kinzel
Engeser GmbH
At Roche, we were looking for a modular, flexible solution for assembling different devices and found this solution in ESSERT´s automation platform. The collaboration with ESSERT was characterized by a high level of innovation and the willingness to adapt to the requirements of the pharmaceutical industry.
Philip Schneider
Drug Product Manufacturing Network Technology Lead at Roche
ESSERT’s standardized robotics platform guarantees fast availability and makes it more cost-effective than classic special solutions.
Martin Rasch
HUMMEL AG
The robot workstation impresses with its flexibility, scalability and integration of state-of-the-art camera technologies.
Arno Schroff
Department manager for plant and site development at Vetter
Thanks to the software and hardware modular architecture of the ESSERT MicroFactory, you can produce with unprecedented flexibility. Exchange process modules or the entire production sequence at a later date.
Integrate your existing machines or manual workstations into the existing production chain.
The Process Control Center (PCC) paired with our ESSERT OS is the command center of your MicroFactory.
The Performance Dashboard allows you to monitor all plant processes and bundle relevant data in a central location.
Data visualization: Extensive data and process visualisation as well as the possibility to create your own dashboards.
Central recipe management: Manage all recipes via a central recipe database and quickly activate & prepare products.
Coordination: The Process Control Center coordinates the overall production flow and ensures 100% good parts.
MES connection: Central interface to your production planning systems.
GMP pre-series validation for even more convenience
Make lengthy revalidation processes of the entire production a thing of the past! With the possibility to prevalidate your individual modules, you can easily modify existing production workflows.
By providing you with prevalidated elements, we can help you to save time and resources while quickly integrating new or modified robotic modules – for uninterrupted, flexible productivity.
Discover our scalable MicroFactory solution for syringe and PEN assembly in variable batch sizes as well as high format variance without setup operations.
What makes the architecture of the ESSERT MicroFactory special?
The uniqueness of our systems lies in their high degree of modularity and flexibility. This allows for the adjustment of the level of automation in a process as needed. While a single ADVANCED Robotic Workstation module can handle individual process steps, multiple workstations can be combined to form a MicroFactory. This enables the comprehensive automation of process chains.
Additionally, our process modules are particularly flexible due to their standardized base. Different configurations may be chosen and changed as needed.
What is the importance of process automation in the general and pharmaceutical industry?
Process automation holds significant importance in the general, but also in the pharmaceutical industry, bringing advantages to aspects like:
How can the ESSERT MicroFactory improve production flexibility?
ESSERT MicroFactory’s software and hardware modular architecture enhances flexibility. You can exchange process modules or the entire production sequence as needed. It seamlessly integrates existing machines or manual workstations into your production chain. This scalability and adaptability give you full control over your manufacturing processes, allowing you to respond quickly to changing requirements.
What are areas of application for the ESSERT MicroFactory?
Our MicroFactory is the right solution for High Mix / Low Volume manufacturing. The manufacturing line is successfully applied in life science and general industry. Its high format variance without setup operations is highly valued – not only for flexible assembly of medical devices like syringes, PENs or auto-injectors, but also for various manufacturing processes in the general industry.
Can individual modules operate independently?
Yes, individual modules of our ADVANCED Robotic Workstation can operate independently, thanks to their own PLC (Programmable Logic Controller). They can either handle a consistent process section or complete production workflows.
To increase speed and versatility in production processes, multiple ADVANCED Robotic Workstations can be assembled into an ESSERT MicroFactory.
Is it possible to involve skilled workers in the process chain (manual workstations)?
Yes, the combination of manual and automated steps is possible. Our systems adhere to the highest safety standards for human-robot collaboration. This allows specific tasks, such as inspection or packaging, to be manually performed while ensuring safety.
Can existing facilities be integrated into the automation process?
Yes, existing facilities can be integrated into automated processes. Our flexible process automation solutions offer numerous interfaces, allowing ADVANCED Robotic Workstations to connect to existing customer facilities and automate previously manual tasks.
Can it be retrofitted and reconfigured for other products?
Yes, the manufacturing network of an ESSERT MicroFactory can easily be adapted by supplementing with additional process modules or by exchanging existing modules for others.
Is it possible to produce multiple products?
Yes, it is possible to produce multiple products. The Process Control Center of a MicroFactory allows quick switching to different product recipes. All recipes can be managed centrally in a recipe database, and new products can be learned without specific expertise.
How long does it take to switch to new products?
Switching to new products typically takes only a few minutes using the Process Control Center. The transition occurs with minimal physical adjustments and is usually done on software level or with only few manual steps.
Are many format parts needed when switching to new products?
No – our systems eliminate the need for rigid mechanical components that require extensive reconfiguration when changing products. Instead, they utilize flexible component feeders that undergo a software-based and fully automatic setup during the changeover.
What analysis capabilities does the MF provide for production?
The Process Control Center allows for a comprehensive overview of all relevant process data and parameters. Extensive analysis tools are also available through the platform, providing a high level of transparency and traceability for automated processes.
Can the system be used in a cleanroom?
Yes, in the GMP-compliant version, both the ADVANCED Robotic Workstation and the ESSERT MicroFactory can be used in cleanrooms up to ISO Class 5. This is achieved through a hygienic design optimized for the pharmaceutical industry, based on stainless steel.
High Mix / Low Volume (HMLV) manufacturing meets the growing customization needs in industries like life sciences. ESSERT Robotics offers solutions for diverse industries, especially in low volume medical device assembly.
High Mix / Low Volume is an increasingly prominent production approach in the pharmaceutical sector. This correlates with the rise of advanced therapies that are custom-made for a small group of individuals – or even one single patient.
This article explains the two different production methods, High Mix / Low Volume (HMLV) & Low Mix / High Volume (LMHV) and compares the advantages and disadvantages of both strategies.
With the manufacturing world moving towards more personalized products and unique market segments, LVM is gaining significant traction. Industries ranging from electronics to life sciences have decided for LVM to successfully supply their unique clientele.
We clarify your automation goals in a non-binding, approx. 30-minute consultation and send you a non-binding offer afterwards. We look forward to getting to know you. Alternatively, feel free to call us directly:
+49 (0) 7251 32641 30
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Contact our team
We would be happy to discuss with you how our robotic platform can help to achieve your goals.