ASSEMBLING WHAT MATTERS
Medical devices.
One process.
Modular assembly and packing cells for a high mix of devices: standardized core functions, recipe-based changeover, inspection built in.
THE PROBLEM
One machine per product never pays off at your volumes.
MedTech device manufacturing is the whole chain from component to sealed pack: feeding, joining, marking, inspection, kitting, packing, blister sealing. Across a portfolio where no two devices are alike.
Dedicated automation is sized for volumes you don’t have
A machine built for one device needs that device to run for years. In a high-mix portfolio it idles, and the next product goes back to manual.
The portfolio grows faster than the hall
Every new device, variant or kit wants floor space, engineering time and its own qualification. The hall stays the same size.
Kitting and packing stay manual
Variable kits, complex products, traceability down to the patient: at the end of the line it is still hands, paper logs and a signature.
FOUR MOMENTS
Where we step in.
Your devices change, your process doesn’t have to. From component to sealed pack, we take over assembly, inspection, kitting, packing and blister sealing, on the same core functions.
01
ASSEMBLY
Feeding, joining, marking.
Standardized core functions assemble very different devices, from inhalers to dental brackets, with inspection and labeling built in.
02
BLISTER SEALING
Blister in, Tyvek on, sealed.
Blister and Tyvek feeding to your sealing machine, Tyvek separation and print check, around the clock.
03
KITTING AND PACKING
Complex products, variable kits.
Camera-guided picking and packing of medical products, taught in without coding, traceable down to the single patient.
04
SMALL BATCHES
Cartons for clinical trials and small series.
Top- and side-loading cartons with devices and accessories, changeover under 15 min between batches.
Not sure where to start?
THE OPTIONS
Three ways to build a high mix.
A machine per product
The changeover
format parts, retooling
The next device
a new machine, if the volume ever justifies it
When something changes
re-engineer
Manual assembly and packing
The changeover
retrain, re-document
The next device
more hands, more stations
When something changes
traceability stays on paper
IN PRACTICE
What changes on the floor.
“
With ESSERT’s solution, we have succeeded in automating our existing manual workstation, increasing productivity, and thus increasing the output of our products.
Andreas Mehlich
Head of Engineering, Ypsomed
SOLUTIONS
Solutions for medical device manufacturing.
Medical Product Assembly
Feeding, joining and marking as shared core functions, so very different devices run with minimal retooling.
View solution
Blister Sealing
Automated blister and Tyvek feeding for sealing, with Tyvek separation and a print check.
View solution
Medical Product Packing
Kitting and packing of complex medical products, adjusted by software instead of retooling.
View solution
Flexible Batch Packaging
Top- and side-loading cartons for small batches and clinical trials, with changeover under 15 min.
View solution
FAQ
Questions from everyone at the table.
Will one cell keep up with a changing portfolio?
Yes. Changeover is recipe-based and taught in without coding. A new device means a new recipe and, where needed, a new gripper, not a new machine.
Can the same cell assemble different devices?
Feeding, joining and marking are standardized core functions. They assemble very different products, from inhalers to dental brackets, with minimal retooling.
Where does inspection happen?
In the cell. Vision inspection and labeling are part of the assembly process, so every device is checked where it is built.
How far does traceability go?
Down to the single patient for packed products, and per module with audit trail for every step before.
Do you handle blister sealing and Tyvek?
Yes. Blister and Tyvek feeding to your sealing machine, Tyvek separation and print check, fully automated.
What about clinical trial packs and small series?
Flexible Batch Packaging packs devices and accessories into top- or side-loading cartons with changeover in under 15 minutes between batches.
Can we start with one cell?
Yes. Each module has its own controller and runs standalone. When the next device comes, you add modules and the qualified ones stay as they are.
Can the cells run in a cleanroom?
Yes. The GMP version in stainless steel is designed for cleanrooms up to ISO 7.
