Flexible and modular
medical device assembly
We help you to future-proof your medical device assembly: Increase production quality and save valuable time.
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
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.
MicroFactory
modules for medical
device assembly
Laser marking of auto-injectors
Assembly of syringes and auto-injectors
Workpiece carrier setup
Automatically setup the workpiece carries for a specific device assembly and feed them to the automation process.
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
Whether Backstop or Extended Finger Flange, feed your attachments as bulk material, and they will be assembled right on the spot.
Plunger rod Feeding
Feed your plunger rods for the syringes assembly as bulk material and they will be assembled right on the spot.
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
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
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
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
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.
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 ADVANCED Robotic Workstation 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.
Clients
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.
The robot workstation impresses with its flexibility, scalability and integration of state-of-the-art camera technologies.
Frequently Asked Questions
Can the MicroFactory line produce both syringes and autoinjectors?
Yes, within a production line, both syringes and autoinjectors can be manufactured. Switching to new product components is simple and can be done at the press of a button, purely on the software side, within minutes.
What is medical device assembly?
Medical device assembly refers to the process of putting together various components and parts to create a finished medical device, such as a syringe, surgical instrument, diagnostic device, or implantable device. This assembly process can involve a wide range of tasks, including precision assembly, quality control, sterilization, and packaging. It is a critical step in the manufacturing of medical devices, as the proper assembly ensures the device’s functionality, safety, and effectiveness for use in healthcare settings.
How can automation improve medical device assembly?
Automation can significantly enhance the efficiency, consistency, and quality of medical device assembly in several ways:
- Precision and accuracy: Automated systems can perform intricate and precise assembly tasks with a high degree of accuracy, reducing the risk of human error.
- Increased speed: Automation can accelerate the assembly process, leading to higher production rates and reduced manufacturing time.
- Consistency: Automated systems ensure that each device is assembled identically, eliminating variations that can occur with manual assembly.
- Quality control: Automated systems can incorporate quality control checks at various stages of assembly, ensuring that only defect-free devices proceed to the next step.
- Traceability: Automation allows for the tracking and documentation of each device’s production history, which is crucial for regulatory compliance and product recalls, if necessary.
- Reduced labor costs: Automation can lead to a reduction in labor costs over time, as it decreases the reliance on manual labor for repetitive tasks.
- Safety: Certain medical devices require sterile environments, and automation can help maintain cleanliness and reduce the risk of contamination.
Read more: Efficiency gains with automation in pharmaceutical industry
What is HMLV device assembly?
HMLV, which stands for High Mix / Low Volume, refers to a manufacturing approach commonly used in the medical device industry. In HMLV device assembly, the emphasis is on producing a wide variety of medical devices in relatively small quantities. This is in contrast to high-volume manufacturing, where a single product is produced in large quantities.
Can the ESSERT MicroFactory 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.
How long does it take to switch an ESSERT MicroFactory to new products?
Switching to new products typically takes only a few minutes using the provided operator tablet or the Process Control Center. The transition occurs with minimal physical adjustments and is usually done on software level or with only few manual steps.
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.
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.