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Device Assembly
MicroFactory

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

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Flexible and modular medical device assembly

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.

Key Features

Automate Step-by-Step

Start with one process module for a specific good manufacturing process. Gradually add automation to your production as needed.

Modular Qualification

The modular approach to qualification allows a fully qualified acceptance test to be carried out for each module separately.

Easy Installation

All the media required for the MicroFactory line is supplied from module to module using hybrid connectors, making installation easy.

Change-Over in minutes

Thanks to our software-based approach, MicroFactory modules are able to change to a new product setting fully automatically.

Modular by default

The modular platform architecture allows for seamless reconfiguration at any time. Modules already in place remain fully validated.

Software Driven

The Process Control Center (PCC) is a vital hub that seamlessly consolidates all the crucial data of all ESSERT automation systems.

Medical device assembly

The trend toward product customization and decentralized production increases the need for flexibility. Our solution is a perfect fit for 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.

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medical device assembly micro factory example

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

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We help to automate manual processes – worldwide. ESSERT Robotics

MicroFactory
modules for medical
device assembly

Workpiece carrier setup
Syringes Feeding
Feeding of attachements
Plunger rod Feeding
NSD feeder
Labelling
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

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

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.

MicroFactory-Plug-and-Produce

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.
Explore our MicroFactory

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.

Learn more
logo-biotronik
Pfizer Logo
Bayer Logo
Roche Logo
Logo Ypsomed

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.

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

Blog

What's new?

Medical device assembly – 7 crucial considerations for seamless production

Medical device assembly – 7 crucial considerations for seamless production

Automating medical device assembly can significantly benefit companies, particularly in addressing challenges like meeting changing customer demands. Automated solutions have the potential to improve assembly lines and enhance product quality.
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18. Apr 2024
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Automation in medical device manufacturing: 5 reasons for automated medical device assembly

There are several reasons in favor of automation in medical device manufacturing – 5 of them will be discussed in this article.
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11. Apr 2024
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Medical device assembly line: ESSERT MicroFactory of the future

The ESSERT MicroFactory is a powerful and modular solution for medical device assembly. In this article, we will discover its features and benefits.
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10. Apr 2024
How to improve efficiency in High Mix / Low Volume manufacturing?

How to improve efficiency in High Mix / Low Volume manufacturing?

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.
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24. Oct 2023
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Contact

Contact our team

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

+49 (0) 7251 32641 30 sales@essert.com

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