Flexible and modular
medical device assembly

We help you to future-proof your medical device assembly: Increase production quality and save valuable time.

Flexible and modular medical device assembly

High Mix / Low Volume manufacturing of syringes, PENs & auto-injectors.

We provide a flexible manufacturing solution for variable batch sizes and high format variance. As a specialist in cutting-edge robotic life science automation, we offer modular, flexible and scalable robotic solutions for your High Mix / Low Volume (HMLV) requirements with minimal setup time – successfully applied in the assembly of secondary packaging or medical devices as well as in clinical studies.

  • Absolute cost certainty
  • Independent, reliable production 24/7
  • Precise & error-free production
  • Automated solution for small batch sizes
  • Minimal change over time ≤ 15 minutes
  • Flexible and scalable manufacturing

Our Solution

ESSERT MicroFactory

ESSERT MicroFactory –robotic automation

Take your medical device production to the next level with the most advanced production line for High Mix / Low Volume manufacturing.

Flexible composition

Choose from a variety of predefined, standardized process modules.

Autonomous commissioning

Each process module can be independently commissioned, fully tested and quickly integrated.

Plug & Produce

Change the initial configuration of your MicroFactory at any time. Integrate new process modules or replace existing modules.

Manual workstation

Integrate manual processes whenever you choose, e.g. for manual inspection or specific processing steps.

Service friendly

The high degree of standardization of individual components allows 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.

We help you to automate your medical device assembly – worldwide.

We help to automate manual processes – worldwide. ESSERT Robotics

modules for medical
device assembly

Workpiece carrier setup
Syringes Feeding
Feeding of attachements
Plunger rod Feeding
NSD feeder
Auto-Injector Feeding
Laser marking of auto-injectors
Assembly of syringes and auto-injectors
Finished part discharge
Workpiece carrier setup

Workpiece carrier setup

Automatically setup the workpiece carries for a specific device assembly and feed them to the automation process.

Syringes feeding by ESSERT Robotics

Syringes feeding

Fed your prefilled syringes in a tub or Rondo tray to the system. Integrated quality controls monitor the condition of the flange or the presence of the RNS.

Feeding of attachements by ESSERT Robotics

Feeding of attachements

Whether Backstop or Extended Finger Flange, feed your attachments as bulk material, and they will be assembled right on the spot.

Plunger rod Feeding

Plunger rod Feeding

Feed your plunger rods for the syringes assembly as bulk material and they will be assembled right on the spot.

Needle Shield Safety Device feeder by ESSERT Robotics

Needle guard feeder

Fed your Needle Shield Safety Devices trays into the tray drawer. The integrated robot picks and places same onto the respective workpiece carriers. An integrated process station allows for force-displacement controlled assembly.

Labelling by ESSERT Robotics


Your devices are directly provided with the appropriate labels during the process. The quality of the thermal transfer or CO2 laser imprints is monitored inline and defective labels are sorted out directly.

Auto-Injector Feeding

Auto-Injector Feeding

Fed your auto-injectors with our autonomous tray stacker module. Integrated quality controls monitor the condition of the auto-injectors.

Laser marking of auto-injectors

Your devices are directly provided with the appropriate laser markings during the process. The quality CO2 laser imprints is monitored inline and defective markings are sorted out directly.

Assembly of syringes and auto-injectors

Assembly of syringes and auto-injectors

Whether syringes assembly or auto-injectors, assemble your medical devices right on the spot to finished products. Integrated quality control monitor the condition of the devices.

Finished part discharge by ESSERT Robotics

Finished part discharge

Your fully assembled devices are removed automatically by the robot and get placed in a tray. The trays can be stacked on a trolley by a tray stacker and thus made available for downstream packaging processes.

High Mix / Low Volume device assembly

The trend toward product customization and decentralized production increases the need for flexibility. Our solution is a perfect fit for High Mix / Low Volume medical device assembly at an output rate of 15 ppm.

Specializing in syringes, PENs & auto-injectors, the device assembly MicroFactory enables fast, automated changeover to new products and minimizes manual labor. Read more: How to improve efficiency in High Mix / Low Volume manufacturing.

medical device assembly micro factory example

Single process to full automation

With the ESSERT MicroFactory, you can align individual manufacturing steps to a fully automated production process.

  • Standardization: Our standardized robot modules provide the perfect basis for your processes.
  • Process Modules: Perfectly designed, standardized process modules to meet any application.
  • ESSERT MicroFactory: Probably the most intelligent and flexible interaction of processes to form a scalable manufacturing line.

Pre-series validation

Use our standardized process modules to automate your manual processes.

You can validate the automated processes in the pre-series and later transfer them to a MicroFactory with little effort, thus scaling your production.


Real businesses,
real results.

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

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

Frequently Asked Questions

Can the MicroFactory line produce both syringes and autoinjectors?

What is medical device assembly?

How can automation improve medical device assembly?

What is HMLV device assembly?

Can the ESSERT MicroFactory be used in a cleanroom?

How long does it take to switch an ESSERT MicroFactory to new products?


What's new?


Contact our team

We would be happy to discuss with you how our robotic platform can help to achieve your goals.

Moritz Latzel Essert
Stephan Fundinger

What can we do for you?

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