Automate the assembly of valuable syringes. Switch smoothly between different sizes, formats and components – with ESSERT’s Syringe Assembly Solution of the ADVANCED Robotic Workstation.
What is syringe assembly?
Syringe assembly is an essential part for several areas in life sciences, bringing together several components to create prefilled syringes as central liquid transfer devices.
There are several cases where mass production of syringes is not a viable option. In these cases, manual syringe assembly is a frequently chosen approach – with several downsides to it. Automation helps to streamline the process of syringe assembly, increasing resource efficiency, safety and product quality.
SYRINGES ASSEMBLY SOLUTION
Automatic syringe assembly machine
The Syringe Assembly Solution of ESSERT’s ADVANCED Robotic Workstation is so much more than an automated syringe assembly machine.
With AI-supported 3D camera technology and real-time quality checks, it makes sure that syringes of various sizes and formats meet the standards that medical devices justly have to meet. And thanks to its modular design, it can be customized for various other tasks that have so far lacked of automation.
Advantages of our ADVANCED Robotic Workstation | Syringe Assembly Solution
The Syringe Assembly Solution of ESSERT’s ADVANCED Robotic Workstation takes the production of sensitive consumables for medical and research purposes to a whole new level. High precision, versatility and scalability are the assets that make this syringe assembly machine so unique.
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.
The robot workstation impresses with its flexibility, scalability and integration of state-of-the-art camera technologies.
Syringe assembly – mass production isn’t always the way to go
When speaking of syringe assembly, the desire for high-speed, mass production may seem like the obvious choice, particularly within the pharma industry.
However, it often requires a more personalized approach. Mass production may not cater to the specific needs and intricacies involved in crafting syringes for specialized applications.
Syringes in HMLV production – personalized medicine on the rise
The rise of personalized medicine has brought with it a growing demand for individualized solutions. Patients now require syringes designed to meet their specific medical needs, resulting in a shift towards more flexible High Mix / Low Volume (HMLV) assembly processes.
This evolution in production, driven by the unique requirements of personalized medicine, is reshaping the way syringes are manufactured and highlighting the importance of adaptable assembly solutions – “one size fits all” approaches are often not up to the mark.
Plastic or glass syringe? Plunger rod and backstop type? Depends
The world of syringe assembly is as diverse as the components that make up a syringe. From the syringe barrel to the needle hub, the plunger rod to the backstop and different flanges, there's a wide array of components, materials, and configurations.
Glass syringes, plastic syringes – the choice varies based on specific needs. This diversity, while essential for medical flexibility, poses unique manufacturing challenges due to the ever-evolving demands and variations in syringe designs.
Automated syringe assembly: The advantages
Automated syringe assembly offers unparalleled benefits. It ensures uniform product quality, rigorous quality control, reduced risk of human errors, increased efficiency, and compliance with cleanroom standards.
Uniform product quality
Achieving consistent product quality is not negotiable in syringe assembly. Automation is the linchpin to this objective.
Precise robotic systems, equipped with advanced 3D camera technology and real-time quality checks, ensure that syringes of various sizes and formats meet exacting standards.
The result is a dependable and uniform product quality, free from variations or defects, crucial in the healthcare industry where precision and reliability are essential.
Quality control and safety
In the assembly of syringes, quality control and safety are essential. Automated assembly processes, empowered by AI-assisted 3D camera recognition and built-in evaluation mechanisms, ensure stringent quality control measures.
Components like syringes, piston rods, and backstops are meticulously examined for integrity and positioned with precision. This commitment to quality not only upholds the highest industry standards but also enhances safety for end-users. The combination of advanced technology and meticulous quality control ensure that every syringe leaving the assembly line is reliable and safe.
Reduced risk for human errors and product loss
Human errors are an inherent concern in syringe assembly. However, automation is a pivotal solution that substantially mitigates this risk. Automated systems execute tasks with precision and consistency, eliminating the variations that often result from manual labor and minimizing the risk of product loss.
By reducing the reliance on human intervention, automated syringe assembly minimizes the chances of errors such as misalignments, defects, or contaminations. The result is a streamlined, error-resistant process that enhances the overall product quality, safety, and reliability.
Compliance with GMP and cleanroom standards
Adhering to Good Manufacturing Practices (GMP) and cleanroom standards is paramount in syringe assembly. Automation plays a pivotal role in achieving and sustaining compliance. Automated processes inherently reduce the potential for contamination, ensuring adherence to the strict cleanroom requirements.
Additionally, pharmaceutical automation offers precise control and documentation of each step, facilitating GMP compliance by minimizing human intervention, minimizing errors, and maintaining meticulous records.
Reduced down-times are a significant factor in syringe assembly, as automated processes minimize pauses and delays. By automating repetitive tasks, staff members are liberated to focus on more intricate, value-added responsibilities, optimizing their skills and productivity.
This dynamic shift in the workforce increases overall efficiency in syringe production. The synergy between machines and human expertise accelerates production rates, lowers costs, and enhances the capacity for meeting demands.
Syringe assembly with ESSERT Robotics
ESSERT Robotics supports you in making syringe assembly more convenient, efficient and safe. The Syringe Assembly Solution of the ADVANCED Robotic Workstation can automatically assemble various types of syringes, depending on what your current requirements are.
The platform is easily customizable via the intuitive ESSERT OS. This operating system allows you not only to monitor ongoing processes, but to modify them with no programming skills necessary.
With ESSERT Robotics, you are prepared for the high demands of syringe assembly in High Mix / Low Volume manufacturing – a production approach becoming more requested in the life sciences industry day by day.
ADVANCED Robotic Workstation – the base for our Syringe Assembly Solution
Based on our ADVANCED Robotic Workstation, we have developed the Syringe Assembly Solution: It unites highest precision and customizability with the conveniences of automation.
Being adaptable with different modules, the ADVANCED Robotic Workstation does not only excel in syringe assembly, but can be used as a scalable automation platform for various kinds of repetitive tasks that require a constant level of precision and regulatory compliance.
MicroFactory – from lab scale to HMLV production
The ESSERT MicroFactory is composed of multiple ADVANCED Robotic Workstations, assembled to take over entire lab and manufacturing processes. The modular and scalable design allows you to adapt different production steps quickly and effortlessly – be it automated pipetting, the assembly of valuable syringes or testing and packaging of medical products.
With ESSERT, compliance with regulatory standards is a matter of course, thanks to the GMP-conform design, ongoing documentation and the possibility for you to monitor processes in real-time while freeing up staff for tasks where they are really needed.