Technical Resources
Case Study
Solving Labor Efficiency and Precision in Pharmaceutical Dispensing
PrimeTest® Automation was contacted by a leading pharmaceutical manufacturer with a specific set of challenges driven by labor inefficiencies and the increasing need for precise, high-speed dispensing in their pill packaging processes. Located in a region with high labor costs, they sought to enhance productivity while maintaining strict accuracy standards and preparing for a rise in demand that would strain their existing manual processes.
The Challenges​
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Labor-Intensive Processes and High Cost of Errors:
The client’s existing production process relied heavily on manual labor to kit unique combinations of pill doses. This approach not only involved high labor costs but also carried a high risk of human error, particularly in counting and organizing pills per kit. With growing demand, these issues risked becoming more frequent, requiring a streamlined and more accurate approach to batch dispensing. -
High-Speed, High-Accuracy Dispensing Requirements:
Given the expected increase in order volume, the client required an automated system capable of processing one kit per second with extreme accuracy. Each kit was custom ordered, including specific pill types and counts. This necessitated a highly precise dispensing system that could accurately differentiate pills based on color and size while ensuring no delays in throughput. -
Complex Order and Inventory Management Integration:
The client’s dispensing process had to interact seamlessly with their ERP system to receive orders, track batches, and confirm completions. This process required real-time tracking of each batch with comprehensive order-tracking capabilities. Additionally, each kit needs to be monitored and tracked across multiple concurrent production lines, with updates being relayed to a customer Manufacturing Execution System (MES). -
Compliance with Clean Room Standards and Usability Requirements:
The client’s clean room environment required easily cleanable components and a system that could be disassembled for washing and maintenance. The automation solution also had to allow for the interchangeability of pill dispensing modules to address issues related to allergen contamination and usability in a controlled environment. -
Pill Singulation Across Multiple Geometries:
The client worked with pills in a variety of shapes and sizes, requiring custom singulation and dispensing stations to ensure precise handling for each type. -
Spatial Constraints and Installation Requirements:
The system had to fit through doorways and elevators, necessitating a modular design that could be easily broken down into subcomponents for convenient transport and reassembly on-site.​​
​​The Solutions Delivered by PrimeTest Automation
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Automated High-Speed Dispensing with Complete Camera Inspection:
PrimeTest® Automation designed a high-speed dispenser integrating a multiple Keyence AI Vision Systems for pill differentiation based on color, size, and type. This solution allowed each capsule to undergo complete inspection, ensuring accurate counts and eliminating human processing error. This system met the client’s one kit per second requirement, while providing the accuracy needed for pharmaceutical production and allowing pills to be kitted into Washable Dosing Vessels. -
Integrated ERP and MES Order Tracking System:
By integrating with the client’s ERP and MES systems, PrimeTest® Automation enabled real-time tracking for each kit. RFID tagging on each individual dispensing cup allowed orders to be tracked from start to finish, with updates relayed directly to the MES. This comprehensive tracking capability ensured accuracy, minimized the risk of mix-ups, and enhanced transparency in the order management process. -
Robust Usability and Clean Room Compliance:
The system featured modular, interchangeable stations for easy cleaning and maintenance, ensuring compliance with ISO clean room standards and eliminating allergen concerns. These stations were designed for rapid disassembly and reassembly, simplifying the wash cycle and maintenance tasks required in the clean room environment. -
Customizable Pill Singulation for Multiple Geometries:
PrimeTest® Automation developed geometry-specific singulation wheels that could be used interchangeably within a common feeder base, enabling the system to accommodate various pill shapes and sizes efficiently. This customization ensured that each type of pill could be dispensed accurately, at high speeds, while minimizing product waste and preserving the system’s efficiency. -
Optimized Space-Saving and Modular Design:
To accommodate the client’s spatial constraints, PrimeTest® designed a modular system that could be broken down into subcomponents capable of fitting through doorways and elevators. This design made transportation and installation significantly easier and ensured that the system could be assembled on-site without requiring structural modifications. -
Enhanced Cup Singulation with SCARA Robots and Precision Packaging:
The client’s previous system, which PrimeTest® Automation had originally developed, utilized lead screw/auger technology for cup singulation and spacing. While this system supported a semi-manual process effectively, the growing customer demand and the need for higher speed operation created challenges.
To address these issues, the manual operation was replaced with SCARA robots equipped with end-of-arm tooling (EOAT) grippers to dispense the cups accurately into on demand packaging systems. Once the pill kits were assembled, each kit was packaged into a heat-seal bag. Fanuc SCARA robots lifted cups from the conveyor and accurately positioned them over the automated packaging system before inverting the cup into the packaging chute. This improvement significantly increased efficiency and reliability as many potential operators’ errors were removed from the system. Beyond singulation, the upgraded system streamlined downstream operations to meet traceability and data-tracking requirements, each bag received a unique variable data print generated by the client’s MES. The heat-sealed bags were then organized into batches based on customer specifications before being unloaded in the designated shipping area, ensuring uninterrupted delivery preparation.
By upgrading the design from the earlier system to this advanced SCARA robot-based solution, the client achieved greater accuracy, improved productivity, and a robust process capable of meeting their evolving needs.
The Outcome
PrimeTest® Automation’s solution provided the client with a high-speed, high-accuracy automation system that reduced labor costs, increased productivity, and improved order accuracy. By meeting the client’s stringent requirements for speed, tracking, and cleanliness, PrimeTest enabled a scalable solution that allowed the client to adapt to growing demand and maintain regulatory compliance in a highly controlled pharmaceutical environment.
To learn more about PrimeTest's® robotics experience and how we can help you develop a custom integrated system, visit our robotics page or