How it all began: The customer was looking for a system that would fully automatically pack individual eye-drop packages into outer cartons in large quantities. Soldati AG developed and built such a system. It marked the start of a successful partnership — as several expansions would follow, eventually leading to a fully automated production line.

The images show the current status of the automation line, built in three phases. The products to be packaged (or repackaged) are vials of eye drops; these are packed with the package insert into small, individual boxes, just as they are sold in pharmacies and drugstores.

The project began with the L-shaped frame featuring the two robots, Max and Moritz.

The first robot cell with Max: Here, the robot fully automatically retrieves the flat cardboard boxes one by one from the stack in one of the two drawers, erects them, and seals the flaps. It completes this in just under 10 seconds.

The second robotic cell, featuring Moritz, is the packaging station. Here, he takes the prepared carton as it arrives from the first robotic cell. The products to be packaged are conveyed in — previously banded in bundles of three — and are now inserted into the cardboard boxes prepared by the robot in units of 6, 12, 18, or 24 (depending on the order).

With the two stations available, this process occurs alternately, so that the robot picks up the filled carton and places it on the conveyor belt in front of the carton sealer. The sealer closes the carton by gluing the top flaps together — and the packaging is complete.

This was the first step in automation.

In the overview image, the expanded system can be seen in the background on the left, featuring the banding and labeling automation that was retrofitted later.

The further increased level of automation (not visible in the pictures) for erecting the individual packages with automatic loading of products and inserts underscores the high level of customer satisfaction, as Soldati AG was once again commissioned as the general contractor for this final expansion phase.