Automation in the pharmaceutical industry

Many companies in the pharmaceutical and medical industries face the same challenge. Production processes are expanding, but they remain dependent on manual steps. This leads to variations in output and increases reliance on staff.

Automation is not an end in itself, but a way to make processes more stable and efficient.

At Van Wees Waalwijk, an automation project always begins with an analysis of the production process. Where do bottlenecks occur? Which tasks are repetitive or error-prone? And which process steps require high precision, controlled handling, or reliable quality control?

Based on that analysis, a customized automation solution is developed that is tailored to the product, the process, and the production environment.

1. Custom Machine Building for Unique Production Processes
Production processes in the pharmaceutical industry are often highly tailored to a specific product or component. As a result, standard machines do not always align well with practical requirements. Through custom machine building, Van Wees Waalwijk develops machines that are fully tailored to the customer’s production process. This involves combining various technologies into a single integrated solution, such as:

• robotics for automated assembly
• motion systems for precise positioning
• Ultrasonic welding for joining components
• Heat staking for mechanical joints
• vision systems for quality control
• laser marking for product identification
• Leak testing for product inspection
• PSA foil applicators for applying foils
• high-precision product handling
• Custom-made carriers for product transport
• automated final assembly

By integrating these techniques, we create a custom-built machine that fits seamlessly into the entire production process.

2. Production Automation for Repetitive Tasks
Many steps in pharmaceutical production processes consist of repetitive tasks such as positioning, assembling, processing, or inspecting components. Automating these steps results in a more consistent production process. Robotics, vision systems, and motion control make it possible to execute processes with precision and reproducibility.

3. Integration into existing production lines
Automation does not always mean that an entire production line needs to be replaced. In many situations, automation solutions can be integrated into existing production lines. By implementing automation in stages, production can continue uninterrupted, and the process can be improved gradually.

Automation in the pharmaceutical industry requires a different approach than in many other sectors. Production processes must not only be efficient, but also verifiable, reproducible, and compliant with various regulations and standards.

For this reason, when developing IT solutions for this sector, a number of key considerations are taken into account as early as the design phase.

1. Hygiene and Cleanroom Environments
   Many pharmaceutical manufacturing processes take place in controlled environments such as cleanrooms. Machines must therefore be designed with a focus on hygiene, maintenance, and integration into these production environments. Van Wees Waalwijk is familiar with the regulations and standards that apply in such production environments and takes these into account when designing and building automation machines.
2. Precision Product Handling
   Products and components in the pharmaceutical industry are often small, delicate, or manufactured with high precision. Correctly positioning, transporting, and assembling these parts therefore requires controlled product handling and high precision.
3. Traceability and Quality Control
   In pharmaceutical manufacturing processes, it is important that process steps remain verifiable and transparent. Automation can help integrate checks and verification steps into the manufacturing process.
   Vision systems, laser marking, and testing processes make it possible to inspect and identify products during the manufacturing process.
4. Stability and Reproducibility
   Pharmaceutical manufacturing requires processes that operate consistently. Automation helps ensure that operations are performed in the same way every time, making production processes more stable.

In many manufacturing environments, standard machines are used for general processes. In the pharmaceutical industry, this is not always possible. Products, components, and manufacturing processes often vary depending on the application.

Custom machine building becomes a viable option when a standard solution does not adequately fit the production process or when a specific process step requires particular standards for handling, precision, or quality control.

At Van Wees Waalwijk, custom machine building is employed when automation must be fully tailored to the product and the production process.

Many components in the pharmaceutical industry are small and delicate. Correctly positioning, moving, and assembling these parts requires specialized solutions.

Special-purpose machines are therefore designed with a focus on controlled product handling and precise positioning.

Combining complex process steps

Manufacturing processes often consist of several steps, such as assembly, quality control, and component processing.

Custom machine building makes it possible to combine multiple process steps into a single integrated solution.

Integration into existing production lines

New machines must be compatible with existing production lines and processes. That is why the design always takes the entire production line into account.

These projects demonstrate how automation can contribute to more efficient production processes in the medical and pharmaceutical industries.

Van Wees Waalwijk developed an assembly machine for medical components for Helvoet. This custom-built machine combines various technologies, including robotics, ultrasonic welding, motion systems, vision technology, and leak testing.

The machine automates various steps in the assembly process, thereby ensuring a reliable and repeatable production process.

Partnership with Helvoet Tilburg

The partnership with Helvoet demonstrates how automation can help improve production processes in the medical industry. By combining technical expertise with practical experience, we create a solution that meets the specific requirements of the production process.