# ESSERT Robotics, Full Knowledge Base > ESSERT Robotics is a German manufacturer of modular, flexible, and scalable robotic automation for pharmaceutical and MedTech production. Headquartered in Bruchsal, Germany, with a North American subsidiary in Raleigh, North Carolina (ESSERT Robotics Pharma Corp.), ESSERT serves over 100 life science customers worldwide with 450+ robotic modules deployed globally. The company is certified to DIN EN ISO 9001:2015 and its MicroFactory Ecosystem has won the FANUC Innovation Award (2023) and multiple RAYA Awards (2025). ESSERT's core solutions cover Fill & Finish (RoboTub, RoboTub SteriFill, RoboVial), Assembly & Inspection (MicroFactory Ecosystem, Syringe Assembly, Autoinjector Assembly, Device Assembly Lab Scale, Medical Product Assembly, ALVA HMLV Visual Inspection with Körber Pharma, Speed Bin Picking, Tub/Rondo Tray Retrayer), and Packing & Sealing (Blister Sealing, Medical Product Packing, Flexible Batch Packaging). All solutions are GMP-compliant, cleanroom-compatible up to ISO Class 5, and built on the proprietary MicroFactory platform with Plug & Produce interfaces. Trusted by Roche, Vetter Pharma, Ypsomed, Pfizer, Bayer, AbbVie, and other global pharmaceutical and medical device manufacturers. --- ## Company Overview **Legal Entity:** ESSERT GmbH (DE) and ESSERT Robotics Pharma Corp. (US) **Founded:** May 2012 by Christopher Essert **Global Headquarters:** Bruchsal, Germany (Triwo Technopark, ~4,000 sqm production area) **North American Headquarters:** Morrisville (Raleigh), North Carolina, USA, live since 2025-01, fully operational from 2026-04-01 **Sales & Service Hub:** Cologne, Germany **Certification:** DIN EN ISO 9001:2015 **Ownership Structure:** Founder-led company with strategic healthcare PE backing. Christopher Essert (founder & CEO) has held a significant stake since incorporation in 2012 and continues to hold a meaningful shareholding alongside SHS Capital, the Tübingen-based healthcare specialist private equity investor that took a majority stake in August 2023. **Website:** https://essert.com **Contact:** +49 7251 32641 00 (General) | +49 7251 32641 30 (Sales) | +49 7251 32641 90 (Service) | info@essert.com | sales@essert.com **Market Focus:** Pharmaceutical and medical device manufacturing. Specialization in high-mix/low-volume (HMLV) production for biologics, personalized therapies, autoinjectors, syringes, and combination products. **Differentiators:** - True modular architecture with "one process, one module" philosophy - Plug & Produce interfaces for rapid integration and changeover - Software-driven autonomous configuration (changeover in minutes vs. hours for traditional systems) - FDA and EU GMP compliant from concept through operation - Batch size 1 capability without efficiency loss - Cleanroom compatible up to ISO Class 5 - Modular qualification: pre-qualify each module before shipment; revalidate only newly added modules **Customer Base:** Vetter Pharma, Roche, Pfizer, Bayer, AbbVie, Ypsomed, Körber, SHL Medical, and other global pharmaceutical, biotech, and medical device manufacturers (100+ in total, primarily in DACH and North America). --- ## Milestones - **2012:** Foundation of ESSERT GmbH in May 2012 by Christopher Essert - **2016:** Awarded the German Innovation Award of the Industry 4.0 Alliance - **2018:** Launch of the MicroFactory Ecosystem (in-house modular robotic platform), presented in June 2018 - **2020:** Opening of the Cologne sales & service office - **2021:** DIN EN ISO 9001:2015 certification achieved - **2022:** Relocation to Bruchsal, Triwo Technopark, quadrupled production capacity to 3,000 sqm - **2023-07:** Additional 1,000 sqm production area added - **2023-08:** SHS Capital takes majority stake in ESSERT GmbH; founder Christopher Essert continues to hold a significant minority stake and remains CEO - **2023-11:** FANUC Innovation Award Winner, for the MicroFactory Ecosystem - **2025-01:** Opening of US subsidiary ESSERT Robotics Pharma Corp. in Raleigh, North Carolina - **2025-10:** Multiple RAYA Award Winner (Best Innovation + Audience Award) for the MicroFactory Assembly Line --- ## Leadership Team - **Christopher Essert**, Founder & Chief Executive Officer (CEO) - **Anna Brecht**, Chief Financial Officer (CFO) - **Peter Deisser**, Chief Operations Officer (COO) - **Moritz Latzel**, Chief Sales Officer (CSO) - **Stephan Fundinger**, Sales - **Bernd Gottschalk**, Sales - **Christian Morgenthaler**, Software - **Marcel Kiwus**, Service & After Sales - **Ayhan Akyüz**, Marketing & Communications - **Lara Ritz**, Human Resources --- ## Positioning Statement (Homepage Messaging) **Tagline:** Automation That Evolves as Fast as Medicine. **Core Narrative:** Modern therapies change fast. Traditional manufacturing can't keep up. ESSERT bridges the gap. Biologics, personalized therapies, and shorter product lifecycles are redefining medicine, yet most automation systems remain rigid. When products evolve, manufacturers face costly downtime (slow changeovers disrupt continuous flow), revalidation headaches (every process update requires complex, expensive revalidation), and wasted assets (rigid hardware becomes obsolete the moment needs change). ESSERT redesigned automation from the ground up: modular by design, built for regulated environments, engineered to evolve. **Proof Points:** - 450+ robot modules globally installed - 100+ life science customers worldwide - FDA and EU GMP requirements embedded from concept through operation - Designed to handle new variants and future process changes - Long-term partnership beyond delivery and commissioning --- ## MicroFactory Ecosystem, The Core Platform **URL:** https://essert.com/microfactory/ **Positioning:** Award-winning modular automation platform for life science manufacturing. Covers Assembly, Inspection, and Packing & Sealing. Built on the philosophy: "One Ecosystem. Infinite Possibilities." **Architectural Philosophy:** - **One process, one module**, every production line is broken down into manageable, standardized units; each unit handles exactly one dedicated process - **Start Smart:** Begin with a single validated core process module. Minimal footprint, immediate ROI. - **Plug & Produce:** Dock a second module when capacity is needed. The Plug & Produce interface handles power, data, and logic instantly. - **Scale to Infinity:** Expand into a fully integrated production line tailored to workflow. - **Future-Proof Agility:** Swap modules to adapt to new market needs. The rest of the line remains untouched and validated. **Key Capabilities:** | Capability | Traditional Line | MicroFactory | |---|---|---| | Flexibility | Limited | High (module swap) | | Scalability | Fixed | Infinite (linear or cluster) | | Changeover Time | Hours to Days | Minutes | | Batch Size 1 | No | Yes | | Modular Qualification | No | Yes (per module) | | Future-Proof Investment | No | Yes (module re-use) | **Modular Design Principles:** - Forget rigid, monolithic systems, strict "one process, one module" philosophy - Replicate specific production processes onto dedicated robotic modules - Combine standardized MicroFactory process modules to design a line - Validate and qualify processes individually to minimize regulatory risks early on - Adapt layout seamlessly to fit specific production floor constraints **Fast Commissioning:** - Every MicroFactory module is tested, fully commissioned, and individually qualified using the ESSERT mobile commissioning station before it reaches the customer facility - No complex on-site assembly or lengthy integration phases - Modular Qualification: each unit is fully qualified before shipment - Drastically reduced time-to-market **Instant Setup & Changeover:** - Software-driven approach: the MicroFactory reconfigures autonomously with the push of a button - Software-guided changeovers eliminate manual errors - Intelligent line clearance using camera technology to check every station - Zero mechanical format parts required, no manual hardware swaps needed to change products **Scalability & Adaptation:** - Decouple production capacity from a fixed setup - Add new modules or reconfigure existing ones as product pipeline or volumes change - Expand from a single module to a fully automated line - Risk-free scaling that adapts to market volatility - Reuse existing modules for new products or layouts **True Batch Size 1:** Designed to meet individualization challenges; handles extremely small batches down to one piece without efficiency loss. **One-Button Setup:** Replaces complex mechanical adjustments with intelligent software. Modules configure autonomously at the push of a button to maximize uptime. **Spare Parts on Demand:** High level of standardization reduces warehousing costs. Essential module components are available immediately for rapid maintenance. **Process Control Center (PCC), Software Intelligence:** - Central nervous system of production - Consolidates all critical data into one intuitive interface - Centralized recipe and user management - Real-time performance data analytics - Seamless multi-line orchestration - Native GMP compliance and audit trails **Architectural Flexibility:** - Versatile Configurations: linear, cluster, or hybrid formations - Seamless Integration: fits existing infrastructure without costly facility restructuring **Customer Quote (Roche):** "At Roche, we were looking for a modular, flexible solution for assembling different devices and found this solution in ESSERT's MicroFactory Ecosystem.", Philip Schneider, Drug Product Manufacturing Technology Lead @ Roche --- ## Solution: RoboTub **URL:** https://essert.com/solutions/robotub/ **Award:** FANUC Innovation Award Winner. **Purpose:** Fully automated, collaborative robotic workstation for tub loading and unloading tasks in pharmaceutical Fill & Finish operations. **Problem Solved:** Even production lines with automated filling, inspection, or packaging typically still rely on manual tub loading/unloading, a bottleneck, ergonomic liability, and cost center. **Key Features:** - **Increase Efficiency:** RoboTub is started by one operator per shift; zero human interaction needed until the next loading cycle - **Increase Productivity:** Designed for 24/7 continuous operation - **Easy Integration:** Plug & Produce interfaces, no interfaces to existing systems necessary - **Versatile in Use:** Handles tubs from/to secondary processes like filling, inspection, assembly, packaging - **Fully Collaborative:** Collaborative robot integration enables safe human interaction (pallet changing during operation) - **Minimal Footprint:** Compact design based on the MicroFactory platform **Customer Proof, Vetter Pharma:** "Due to the high level of automation, one single RoboTub module can reduce the number of operators down to 1. The system has already paid for itself after 1 year.", Arno Schroff, Department Manager for Plant and Site Development **Configuration Models:** | Spec | RoboTub Basic | RoboTub Pro | |---|---|---| | Throughput | 3 Tubs/minute (incl. pallet exchange) | 6 Tubs/minute (incl. pallet exchange) | | Material Handling Spots | 1 | 2 (uninterrupted pallet exchange) | | Collaborative Robots | 1 | 2 | | Expandable | Yes, wide range of add-ons | Yes, wide range of add-ons | **Supported Add-Ons & Formats:** - Gaylord Boxes, direct loading/unloading from large-volume Gaylord boxes - Pallets, EU and US standard pallets (48" x 40" US, 48" x 32" EU) - Cases Packing, cartons and packing cases - Lid Assembly, automatic removal or placement of lids on tubs - Divider Layer Handling, precise placement of divider layers in the stacking process - Tub Trays, precise loading and unloading of tubs within tub trays **Pallet Format Compatibility:** - Full support for 48" x 40" (US) and 48" x 32" (EU) pallet sizing - Flexible handling of both 16-Tub and 17-Tub loading patterns to optimize shipping volume **Health & Safety Argument:** Manual tub handling causes musculoskeletal disorders (MSDs), which account for 33% of all worker injury cases and cost US businesses over $50 billion annually. RoboTub eliminates repetitive strain, prevents long-term injury, demonstrates commitment to employee well-being, and frees skilled workers for higher-value tasks. --- ## Solution: RoboTub SteriFill **URL:** https://essert.com/solutions/robotub-sterifill/ **Purpose:** Automated Tub Unboxing and Handling for Sterile Environments in the pharmaceutical industry. Closes the automation gap in aseptic cleanroom Fill & Finish. **Problem Solved:** Even with state-of-the-art automated filling and inspection, the critical step of tub loading/unloading often remains manual, introducing contamination risk, ergonomic challenges, and production bottlenecks in the cleanroom. **Key Features:** - **Boost Efficiency:** Minimal human interaction; single operator manages the entire cycle per shift - **Maximize Productivity:** 24/7 continuous operation, no interruptions or bottlenecks - **Seamless Integration:** Works with current setup without complex system interfaces - **GMP & Safety Compliant:** Built to the highest pharmaceutical standards; collaborative robots for secure working environment - **Fully Collaborative:** Collaborative robots enable pallet exchange during operation and easy maintenance access - **Minimal Footprint:** Compact, modular design based on the MicroFactory Ecosystem **System Capabilities:** - **Multi-Format Ready:** Handles both Ompi and BD boxes for supply chain flexibility - **Pallet Flexibility:** Compatible with EU and US standard pallets - **AGV Ready:** Designed for seamless Automated Guided Vehicle integration - **High Autonomy:** 8–10 minute autonomy time for pallet exchange; 2-box buffer maximizes uptime - **Rapid Deployment:** Modular design enables fast Factory Acceptance Testing (FAT) and Site Acceptance Testing (SAT) - **Proven Foundation:** Built on the award-winning, field-tested RoboTub platform **Three Core Modules (end-to-end solution):** 1. **Unloading Boxes & Waste Handling**, robot unloads boxes from pallets; 2-box buffer for high autonomy; dedicated waste handling 2. **Box Opening & Folding**, automatically opens and folds Ompi and BD boxes at two dedicated stations 3. **Feeding the Filling Machine**, robot unloads tubs; uses cameras to verify orientation before loading into the filling machine --- ## Solution: RoboVial **URL:** https://essert.com/solutions/robovial/ **Purpose:** Fully collaborative robotic workstation that unloads filling lines, tends inspection machines, and precisely packs vials into multi-use boxes. End-of-line automation for Fill & Finish. **Problem Solved:** Filling and inspection machines running at peak performance are bottlenecked by manual unloading and packing, a repetitive, physically demanding task that slows production and exposes workforce to MSD risk. **Key Features:** - **Protect Your Team:** Eliminates repetitive manual lifting; reduces MSD injury risk; improves morale and retention - **Maximize Throughput:** Continuous operation; no manual bottlenecks between filling/inspection and final production - **Seamless Integration:** No complex interfaces with existing filling or inspection machines - **Proven Platform:** Built on ESSERT's field-proven, standardized RoboTub handling modules - **Fully Collaborative:** Certified collaborative robots, no bulky safety fences needed - **Minimal Footprint:** Compact, modular design **Capabilities:** - **Automated Loading, Unloading & Packing:** Unloads filling lines, fully automates loading/unloading of inspection machines, arranges vials in consistent patterns, packs into multi-use boxes - **Multi-Format Ready:** Handles vial sizes 2R to 30R - **Precise Vial Handling:** Pre-orientation system + gentle pushers ensure consistent, repeatable box insertion pattern - **AGV Ready:** Seamless integration with Automated Guided Vehicles for fully automated pallet exchange - **High Autonomy:** Vial buffering keeps the process running during pallet exchange (~4 minutes operator changeover time) - **Rapid Deployment:** Modular design for fast FAT and SAT - **Optional Labeling:** Integrated labeling system for automated box labeling before palletizing --- ## Solution: Syringe Assembly **URL:** https://essert.com/solutions/syringes-assembly/ **Purpose:** Modular, robot-based syringe assembly platform for pharmaceutical and MedTech manufacturers. Built for HMLV production, biologics, personalized therapies, and combination products. **Problem Solved:** Conventional assembly lines are rigid, product-specific, and expensive to modify. Pipelines evolve faster than ever (biologics, personalized therapies, combination products), causing long changeover times, costly revalidation, and underutilized assets. **Key Features:** - **Evolve Your Line:** Start lean; add modules for new process steps (like safety device assembly) only when needed - **Changeover in Minutes:** Software-driven architecture minimizes manual format adjustments; rapid automated changeovers between syringe variants - **Smart Validation:** Each module is pre-qualified; only new additions require validation when expanding - **Investment Security:** Reuse standardized modules across different products; no product-line lock-in - **Faster Deployment:** Modules are fully commissioned before delivery with Plug & Produce interfaces - **Proven Platform:** 450+ automation modules installed globally; trusted in GMP-regulated environments **Configuration Examples:** | Configuration | Modules Included | Use Case | |---|---|---| | Standard Assembly | Syringe feeding, plunger rod assembly, backstop/finger flange assembly, labeling, tray loading | Early-stage production, frequent format changes | | With Safety Device | Standard + safety device feeding and assembly modules | Scaling up to complex combination products | **Architecture Principle:** Built around processes, not products. Standardized modules combined, expanded, and reused as product pipeline evolves. **Digital Ecosystem:** Software architecture ensures adding a module is as close to "Plug-and-Produce" as possible in a GMP environment. Reduces project lead times and operational risk. **Customer Proof, Roche:** "At Roche, we were looking for a modular, flexible solution for assembling different devices and found this solution in ESSERT's automation ecosystem. The collaboration with ESSERT was characterized by a high level of innovation.", Philip Schneider, Drug Product Manufacturing Network Technology Lead **Pre-series Validation:** Customers can automate manual processes using standardized modules, validate in pre-series, and later transfer to a full MicroFactory Line with minimal effort. --- ## Solution: Autoinjector Assembly **URL:** https://essert.com/solutions/autoinjector-assembly/ **Purpose:** Modular automation platform for autoinjector assembly, from early-stage development and design iterations through full commercial scale-up. **Problem Solved:** Autoinjectors are integral to the therapy itself; they directly impact patient safety and dosing accuracy. Rigid, product-specific assembly lines increase risk and create validation bottlenecks as device designs evolve and regulations tighten. **Key Features:** - **Lifecycle Modularity:** Supports autoinjector programs from early-stage development to full commercial scale-up - **Controlled Flexibility:** Design changes are adapted via individual modules; impact is localized; change management simplified in regulated environments - **Predictable Scale-Up:** Add capacity or new process steps (e.g., enhanced inspection) via new modules with standardized interfaces - **Pre-Commissioning:** Each module is fully commissioned and tested before delivery - **Robotic Repeatability:** Critical assembly operations executed by robots with highest precision and repeatability, consistent quality for patient-critical devices - **Localized Changes:** Existing qualified modules remain unchanged when new ones are added; process changes stay controlled and manageable **Software-Driven Architecture:** Every parameter, from joining force to visual inspection, is monitored, recorded, and compliant with GMP standards. **Configuration Principle:** - **Core functions:** Device feeding, primary assembly, final labeling - **Expandable modules:** Functional testing, vision inspection of safety clips, serialization, and more **Customer Proof, Roche:** (same quote as Syringe Assembly) --- ## Solution: Device Assembly (Lab Scale) **URL:** https://essert.com/solutions/device-assembly-lab-scale/ **Purpose:** Lab-scale to production-scale automation for medical device assembly. Starts automating production at the clinical trial stage; brings mass-production reliability to lab-scale and micro-batch manufacturing. **Problem Solved:** For clinical trials and product launches, speed isn't the only metric, flexibility is. Manual assembly introduces variability, contamination risk, and lack of data. **Key Features:** - **Flexibility:** Switch between device formats and packaging types with minimal changeover time - **Scalability:** Move seamlessly from clinical trials to commercial production on the same technology platform - **Process Safety:** Eliminate human error; 100% traceability for every unit assembled - **Future-Proof:** Pre-validated modules that maintain strict GMP compliance - **Minimal Footprint:** Compact design maximizes cleanroom efficiency and reduces operating costs - **Fast Time-to-Market:** Standardized platform minimizes engineering and validation time **Special Strengths:** - GMP & Cleanroom Ready: designed specifically for pharma requirements - Full Traceability: automated documentation replaces error-prone manual logs - Boost Efficiency: relieves staff of repetitive, delicate tasks for process optimization and research **Typical Application:** Autoinjector assembly at clinical-trial scale. --- ## Solution: Medical Product Assembly **URL:** https://essert.com/solutions/assembly-of-medical-products/ **Purpose:** Flexible automation platform for the assembly of diverse medical products on a single MicroFactory-based line. Designed for High-Mix/Low-Volume (HMLV) production where multiple product families (e.g. inhalers, dental brackets, diagnostic devices, drug-delivery components) share the same qualified automation asset instead of requiring dedicated lines per SKU. **Problem Solved:** Traditional assembly automation is optimized for a single product at high volume. When manufacturers need to run small batches across many variants, with frequent design changes, short life cycles, and tight GMP constraints, rigid lines become a bottleneck: slow changeovers, over-capacity on some SKUs, under-capacity on others, and wasted capex when a product is discontinued. **Key Features:** - **Instant Changeovers:** Recipe-based tool and gripper changing enables switching between product variants in minutes, not hours, no mechanical re-tooling - **Universal Feeding:** Feeding systems engineered for complex part geometries across multiple product families on the same cell - **Integrated Quality:** Vision inspection and in-process checks built into each module; 100% per-unit traceability - **Modular Scale-Up:** Start with a single cell; add modules as the product portfolio or volume grows - **GMP & Cleanroom Ready:** Full pharma/MedTech compliance, cleanroom compatible up to ISO Class 5 - **Investment Security:** Modules remain reusable across products, protects capex against portfolio changes **Typical Applications:** Inhaler assembly, dental component assembly (e.g. orthodontic brackets), diagnostic device assembly, drug-delivery device sub-assembly, combination-product assembly in HMLV environments. **Technology Stack:** MicroFactory platform, Plug & Produce interfaces, collaborative robotics, recipe-driven tool changing, integrated vision inspection, Process Control Center (PCC). --- ## Solution: ALVA (HMLV Visual Inspection) **URL:** https://essert.com/solutions/alva/ **Purpose:** ALVA (Adaptive Low Volume Automatic) is Körber Pharma's high-mix/low-volume visual inspection solution for pre-filled syringes, vials, and cartridges, powered by ESSERT Robotics. ESSERT engineered the robotic in- and outfeed automation that makes the inspection deployable in high-mix production. Born from a development partnership: Körber Pharma owns the inspection science, ESSERT Robotics built the robotics around it. Revealed at Interpack 2026 in Düsseldorf. **Problem Solved:** Pharma portfolios are shifting toward smaller batches and more frequent changeovers (personalized therapies, biologics, clinical trial material, CDMO contracts), but most visual inspection systems are built for one container format and long uninterrupted runs. The result: costly manual format changeovers that stall production for hours, detection consistency that drifts between formats, and dedicated inspection cells that sit idle when the portfolio shifts. **Key Features:** - **Format Flexibility:** Syringes, vials, and cartridges handled by one cell, one robotic concept, with fast, predictable changeovers - **Robotic In- & Outfeed (ESSERT):** Precise pick-and-place across formats, gentle motion profiles for pre-filled product integrity, changeover-ready end-of-arm tooling without cell retooling - **Reproducible Detection:** Particle and cosmetic defect detection with consistent recipe logic across formats and batches - **Performance:** Up to 20 containers per minute (sized for HMLV reality), up to 32 minutes autonomous run time per cycle - **AI-Ready:** Architected for deep-learning integration to continuously reduce false-reject rates as the data set grows - **GxP-Ready:** Audit trail, traceability, and validation-ready workflows from concept through operation - **Compact Footprint:** Fits space-constrained cleanrooms without compromising inspection performance - **MicroFactory-Ready:** Integrates with ESSERT's modular platform; extendable with De-Nesting, Re-Nesting, and Labeling modules via Plug & Produce interfaces **Typical Applications:** Visual inspection of pre-filled syringes, vials, and cartridges in high-mix/low-volume pharmaceutical production: personalized therapies, biologics, clinical trial material, CDMO manufacturing. **Partnership Note:** ALVA is a Körber Pharma solution. ESSERT Robotics' contribution is the robotic in- and outfeed automation. More on the inspection solution: https://www.koerber-pharma.com/solutions/inspektion/automatische-inspektion/alva --- ## Solution: Blister Sealing **URL:** https://essert.com/solutions/blister-sealing/ **Purpose:** Fully automated and collaborative robotic workstation for blister sealing and Tyvek handling. Minimal footprint. **Problem Solved:** Manual blister sealing is repetitive, labor-intensive, and limits productivity. **Key Features:** - **Collaborative Robotics:** Compact platform architecture with collaborative robots, minimal footprint - **Blister and Tyvek Feeding:** Fully automated feeding to the sealing machine for higher process efficiency - **Maximize Uptime:** Designed for 24/7 continuous operation - **Increased Efficiency:** Automates repetitive tasks, frees employees for complex work - **Tyvek Handling:** Fully automated separation of Tyvek with printing verification - **Optimized Cycle Time:** 2-arm gripper for optimized cycle time and improved automation efficiency **Customer Proof, Ypsomed:** "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 **Technology Stack:** Intelligent sensors, automated blister and Tyvek handling, advanced robotics, GMP-compliant design. --- ## Solution: Medical Product Packing **URL:** https://essert.com/solutions/packing-of-medical-products/ **Purpose:** Automated packing solutions for medical products with flexible batch handling. Protects products from environmental influences during transport and storage. **Problem Solved:** Packing medical products is highly variable, both the medical product and the type of secondary packaging change regularly. Manufacturers need extreme flexibility. **Key Features:** - **Uncompromising Quality:** State-of-the-art camera and sensor tech for 100% precision - **Instant Adaptability:** Flexible packaging solution easily adapted to varying packaging requirements - **Maximize Uptime:** Reliable, self-running system minimizes supply chain downtime - **Audit-Ready Compliance:** Cleanroom and GMP-compliant design simplifies regulatory compliance - **Empower Your Workforce:** Frees skilled staff for high-value work - **Cut Costs, Not Corners:** Reduces manual errors, minimizes secondary packaging damage, lowers operational costs **Technology:** - **Software-Driven:** Control complex robotic processes via tablet; teach in new packaging formats without programming skills - **Full Traceability:** Audit-ready transparency down to individual patient level - **Sterile & Safe:** Maintains product integrity from production to patient **Where It Excels:** High Mix / Low Volume (HMLV) manufacturing, personalized therapies, specialized pharmaceuticals, intricate medical instruments, diagnostic kits, sterile surgical supplies. --- ## Solution: Flexible Batch Packaging **URL:** https://essert.com/solutions/flexible-batch-packaging/ **Purpose:** Fully automated packing for small batches and clinical trials with near-zero changeover time and minimal footprint. **Problem Solved:** Small batches and clinical trials demand packaging flexibility without sacrificing throughput or compliance. **Key Features:** - **Modular Qualification:** Fully qualified acceptance test performed separately for each module - **Easy Installation:** Media supplied from module to module using hybrid connectors - **Changeover in Minutes:** Software-based approach allows fully automatic product setting changes **Supported Formats:** Top and side loading cartons, multiple devices, accessories for different packaging configurations. **Platform Foundation:** Built on the MicroFactory Ecosystem, modular, scalable, with small footprint and minimal changeover time. Enables efficient, agile move toward personalized medicine and small-batch production. **Architecture Benefits:** - Dedicated Precision: one dedicated process per module; maximum control and efficiency - Unlimited Modularity: process defines the line; requirements replicated on each module - Versatile Configurations: linear or cluster arrangements - Seamless Integration: fits into existing infrastructure without costly restructuring --- ## Solution: Speed Bin Picking **URL:** https://essert.com/solutions/speed-bin-picking/ **Purpose:** AI-driven robotic bin picking for pharmaceutical components (syringes, transparent parts). Breakage-free, flexible, GMP-compliant. **Problem Solved:** Manual bulk separation of pharmaceutical components ties up skilled workforce in tedious sorting. Standard vision systems struggle with glass/transparent components. **Key Features:** - **Seeing the Invisible:** 3D Vision + AI Technology reliably detects transparent syringes in disorganized piles under any lighting condition - **Gentle Touch:** Tactile sensors grip as delicately as a human hand, minimizes glass breakage and product loss - **Ready for HMLV:** Modular system adapts to small batches and frequent product changes - **No Coding:** Software-driven teach-in process, zero programming skills required **Pharma Compliance & Technology:** - Maximum Safety: reduced contamination risk through automation (minimum human-in-the-loop) - Full Traceability: real-time monitoring and documentation of every pick - Space Saver: compact, modular design fits restricted environments **Customer Proof, Vetter Pharma:** "The Bin Picking solution impresses with its flexibility, scalability and integration of state-of-the-art camera technologies.", Arno Schroff, Department Manager for Plant and Site Development **Typical Application:** Bin picking of injection bulk material. --- ## Solution: Tub / Rondo Tray Retrayer **URL:** https://essert.com/solutions/tub-rondo-tray-retrayer/ **Purpose:** Bidirectional automated transfer of syringes between tubs and Rondo trays. Maximum flexibility and throughput. **Problem Solved:** Manual syringe transfer between tubs and Rondo trays is slow, costly, and risks human error and contamination. **Key Performance Specs:** - **Throughput:** 200 parts per minute (PPM) - **Bidirectional Flexibility:** Transfer Tub → Rondo Tray and Rondo Tray → Tub - **Quick Format Changes:** Software-based approach; minimal setup effort; fast format changes for different tray sizes - **Proven Reliability:** Built on MicroFactory Ecosystem with standardized handling modules - **Fully Collaborative:** Collaborative + SCARA robots; no bulky safety fences - **Seamless Integration:** Standalone or with optional automated de-palletizing and outfeed modules **Supported Tray Sizes:** 7, 10, 14, 16, 20 **Core Technology:** - **Multi-Format Gripper:** Specialized gripper places syringes individually; handles various tray sizes; compensates for missing products - **Pitch Adjustment:** Integrated cylinder mechanism automatically converts tub pitch to Rondo tray pitch - **Camera Verification:** Integrated camera systems verify syringe quantity and correct loading - **Large Tray Buffer:** Rondo Tray Module buffers up to 80 trays (4 stacks of 20) for autonomous operation - **Smart Distribution:** Carrier system distributes syringes evenly between two SCARA robots for maximum speed - **Quick Deployment:** Modular design for fast FAT and SAT **Optional Extensions:** - **RoboTub Depalletizing:** Fully automates tub depalletizing from Gaylord boxes; separates nests from tubs; handles intermediate layers - **Rondo Tray Outfeed:** Loads filled Rondo trays into plastic containers; rotating turntable for continuous operation **Customer Proof, Vetter Pharma:** "ESSERT's automation platform impresses with its flexibility and modularity as well as the integration of state-of-the-art technologies.", Arno Schroff, Department Manager for Plant and Site Development --- ## Consulting Services **URL:** https://essert.com/consulting/ **Purpose:** Structured, technology-driven consulting that bridges operations, engineering, quality assurance, and management for pharmaceutical and MedTech automation projects. **Why ESSERT Consulting:** Many automation projects fail due to unclear goals, incomplete requirements, or lack of strategic alignment, not due to technology. ESSERT Consulting solves this with a structured, implementation-focused approach. **Value Propositions:** - **Reduce Project Risk:** Identify and mitigate risks early by defining clear requirements and validating concepts upfront - **Accelerate Timelines:** Strategic roadmap streamlines decision-making and execution - **Ensure ROI:** Data-driven investment decisions; technically sound, economically viable strategies - **Improve Team Alignment:** Bridges departments for unified automation vision - **Future-Proof Solutions:** Modular, scalable design adapts to new products and capacity needs - **Regulatory Compliance:** Deep life-science expertise; GMP compliance from day one **4-Step Consulting Methodology:** 1. **Assessment & Understanding** - In-depth process and workflow analysis - Identify bottlenecks, risks, and manual activities - Review regulatory, GMP, and quality requirements - Align with business, capacity, and growth targets 2. **Automation Strategy & Target Concept** - Identify high-potential automation use cases - Develop concepts for modularity and scalability - Define appropriate levels of automation and flexibility - Evaluate make-or-buy strategies - High-level ROI and investment analysis 3. **Concept Development & System Architecture** - Design process flow and system architecture - Create modular cell and line concepts - Develop strategies for human-robot interaction and cleanroom integration - Plan for changeovers, campaigns, varying batch sizes - Establish digitalization and data integrity concepts 4. **Requirement Definition & Project Preparation** - Create detailed User Requirement Specifications (URS) - Define functional concepts and project boundaries - Address interface and integration requirements - Apply risk-based thinking for GMP, compliance, validation - Prepare RFQs, supplier selection, internal approvals **Typical Consulting Topics:** - Automation Feasibility Studies - Modular Production Concepts - High-Mix, Low-Volume Strategies - Scale-Up & Capacity Expansion Planning - Manual-to-Automated Process Transformation - GMP-Compliant Automation - Digital Factory & Future Production Concepts - Early-Phase Project Definition & Alignment **From Consulting to Implementation:** Consulting outputs can transition seamlessly into implementation: - Modular Automation Solutions, GMP-ready automation cells - Pilot Systems and Proof-of-Concepts, validate strategy with functional prototype - Scalable Production Platforms, MicroFactory-based line that starts small and scales --- ## Customer Service **URL:** https://essert.com/customer-service **Purpose:** Lifecycle service for installed ESSERT systems, protects OEE and validation status from commissioning into long-term production. After-sales experts embed with the customer the moment the machine ships, providing a direct line to the team that built the system through commissioning, ramp-up, and every batch that follows. **Positioning:** "Service Built Around Your OEE." Service starts before the first batch, not after the first breakdown. The result: faster ramp-up, fewer surprises, and an OEE curve that climbs instead of stalls. **Six Service Pillars:** 1. **Digital Connectivity**, Rapid access to specialists familiar with the customer's project. Flexible support windows and advanced remote diagnostics to keep OEE at peak. 2. **Reliability & Maintenance**, Regular inspections for sustained equipment reliability and compliance. Wear identified early; detailed documentation with optimization recommendations. Scheduled inspections, wear-part management, fixed planning intervals for predictable operating costs. 3. **Validation Excellence (PQ Support)**, Dedicated Performance Qualification support to ensure equipment performs consistently within specifications. Experts assist in documenting that all processes meet strict GMP and FDA requirements under real-world conditions. Performance verification, compliance assurance, audit-ready data. 4. **Ramp-up Assistance (Bay Support)**, On-site expert presence during initial production runs. Side-by-side presence at the production bay during startup, real-time monitoring of first batches, operational security during the critical high-risk ramp-up phase. 5. **Practical Empowerment (Training Programs)**, Hands-on sessions for operators and maintenance teams to ensure safe and efficient equipment handling. Customized curricula tailored to the customer's specific machine configuration; technical self-sufficiency for basic maintenance and troubleshooting. 6. **Capital Efficiency (Spare Parts on Demand)**, Flexible on-demand service avoids tying up capital in extensive local inventories. Hardware-specific spare parts shipped directly from ESSERT's warehouse exactly when needed. **Priority Support (Optional Tier):** Defined response times for critical production lines. Guaranteed expert availability, priority handling for spare parts delivery and emergency on-site service visits, tailored coverage levels matched to line criticality. **Why It Matters:** In regulated pharma and MedTech production, downtime is not just an OEE problem, it threatens validation status, batch records, and supply commitments. ESSERT's lifecycle service is designed to protect all three. --- ## Core Technologies (Cross-Solution) ### MicroFactory Platform - Modular process modules with standardized interfaces - Process Control Center (PCC) for centralized management - Real-time performance analytics and GMP audit trails - Versatile configurations (linear, cluster, hybrid) - Mobile commissioning station for pre-shipment qualification ### Plug & Produce - Instant module docking with automatic power, data, and logic connection - Zero mechanical format parts required for product changeover - Software-guided changeovers with intelligent line clearance - Camera-based verification systems ### Collaborative Robotics - Safe human-machine interaction - Minimal footprint for cleanroom environments - 24/7 continuous operation capability - One operator per shift requirement ### Software & Data Architecture - Centralized recipe and user management (via PCC) - Real-time performance data analytics - Seamless multi-line orchestration - Native GMP compliance and audit trails - Teach-in capability without programming skills (for Bin Picking, Packing) --- ## Industries & Use Cases ### Pharmaceutical Manufacturing (Fill & Finish, Sterile Processing) - Automated tub and vial loading/unloading for filling machines - Sterile tub unboxing and handling (Ompi and BD boxes) - Divider layer feeding and lid assembly - Gaylord box handling - Pallet exchange automation (EU and US standard pallets) - Vial handling from filling to multi-use box packing ### Medical Device Assembly - Syringe component assembly (plunger rod, backstop, finger flange, labeling) - Autoinjector and pen device assembly with functional testing - Safety device integration for combination products - Vision-based quality inspection and orientation verification - Medical device assembly from lab to production scale ### Biologics and Personalized Medicine Production - HMLV production with batch size 1 capability - Rapid changeovers for personalized therapies - Modular qualification for frequent product changes ### Contract Development and Manufacturing Organizations (CDMOs) - Flexible assembly lines for multi-customer, multi-product production - Pre-commissioned modules for rapid deployment ### Packing & Sealing - Blister sealing with automated Tyvek handling - Flexible batch packaging for varying product volumes - Secondary packaging automation - Tray loading and handling - Medical product kitting --- ## Customer Success, Case Study Facts ### Vetter Pharma (CDMO, Pharmaceutical) - **Solution:** RoboTub + Speed Bin Picking + Tub Rondo Tray Retrayer - **ROI:** System paid for itself within 1 year - **Operator Reduction:** Down to 1 operator per shift per RoboTub module - **Quote:** "Due to the high level of automation, one single RoboTub module can reduce the number of operators down to 1. The system has already paid for itself after 1 year.", Arno Schroff, Department Manager for Plant and Site Development ### Roche (Pharmaceutical / Biologics) - **Solution:** MicroFactory Ecosystem, Syringe Assembly and Autoinjector Assembly - **Value Driver:** Modular, flexible solution for assembling different devices - **Quote:** "At Roche, we were looking for a modular, flexible solution for assembling different devices and found this solution in ESSERT's MicroFactory Ecosystem. The collaboration with ESSERT was characterized by a high level of innovation.", Philip Schneider, Drug Product Manufacturing Network Technology Lead ### Ypsomed (Medical Device Manufacturer) - **Solution:** Blister Sealing with Tyvek Handling - **Impact:** Automated existing manual workstation; increased productivity and output - **Quote:** "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 --- ## Frequently Asked Questions **Q: How to automate syringe assembly for high-mix/low-volume production?** A: ESSERT's modular Syringe Assembly platform supports all syringe types on one line, with software-driven changeovers in minutes and batch size 1 capability. Modules can be combined, expanded, and reused as the product pipeline evolves. **Q: How to achieve GMP-compliant robotic Fill & Finish automation?** A: ESSERT's RoboTub and RoboTub SteriFill solutions are designed for GMP-compliant Fill & Finish environments with collaborative robotics, camera-based verification, and full audit trail capabilities. Cleanroom compatible up to ISO Class 5. **Q: How to scale automation from lab to commercial production?** A: The MicroFactory Ecosystem allows manufacturers to start with a single module and scale to a full production line by adding standardized modules with Plug & Produce interfaces. Only new additions require validation. **Q: What makes the MicroFactory architecture special?** A: ESSERT replaces rigid production lines with independent, standardized process modules. This architecture delivers unmatched flexibility and scalability, making it ideal for high-mix/low-volume manufacturing. **Q: Can MicroFactory modules be operated separately?** A: Yes. Each module features its own PLC and operates independently. They can run as stand-alone units for specific tasks or be combined to form a complete MicroFactory line. **Q: How does the MicroFactory make production more flexible?** A: Manufacturers can produce various products on one platform and scale automation gradually. The MicroFactory supports hybrid workflows by seamlessly combining robotic modules with manual workstations for safe human-machine interaction. **Q: Is it possible to switch to other products on the MicroFactory?** A: Yes. New process modules can be added or existing ones swapped out at any time. This allows manufacturers to reconfigure their line for new products without replacing the entire system. **Q: Can the MicroFactory system be used in a cleanroom?** A: Yes. With its hygienic stainless steel design, the GMP-compliant version is fully approved for operation in cleanrooms up to ISO Class 5. **Q: What throughput does the RoboTub deliver?** A: RoboTub Basic delivers 3 tubs/minute with 1 collaborative robot. RoboTub Pro delivers 6 tubs/minute with 2 collaborative robots and 2 material handling spots for uninterrupted pallet exchange. **Q: What tub formats does RoboTub SteriFill support?** A: The RoboTub SteriFill is multi-format ready and handles both Ompi and BD boxes. **Q: What pallet sizes are supported?** A: EU (48" x 32") and US (48" x 40") standard pallets, both 16-Tub and 17-Tub loading patterns. **Q: What vial sizes does RoboVial support?** A: RoboVial handles vial sizes from 2R to 30R. **Q: What throughput does the Tub/Rondo Tray Retrayer achieve?** A: Up to 200 parts per minute (PPM), bidirectional. **Q: How does ESSERT reduce revalidation effort when a line is expanded?** A: ESSERT uses modular qualification. Each module is pre-qualified before shipment. When a line is expanded with new modules, only the new additions require validation, existing qualified modules remain unchanged. **Q: Does ESSERT require programming skills to teach new products?** A: No. For Bin Picking, Packing, and MicroFactory modules, products are taught via a tablet-based teach-in process. Zero programming skills are required. **Q: What certifications does ESSERT hold?** A: ESSERT is certified to DIN EN ISO 9001:2015. Systems are FDA and EU GMP compliant, cleanroom-compatible up to ISO Class 5. **Q: Where are ESSERT's locations?** A: Global HQ in Bruchsal, Germany (Triwo Technopark, 4,000 sqm production). North American HQ in Morrisville (Raleigh), North Carolina, USA. Sales & Service Hub in Cologne, Germany. **Q: Who are ESSERT's customers?** A: 100+ life science customers worldwide, including Vetter Pharma, Roche, Pfizer, Bayer, AbbVie, and Ypsomed. **Q: What awards has ESSERT won?** A: FANUC Innovation Award (2023) for the MicroFactory Ecosystem; Multiple RAYA Awards (Best Innovation + Audience Award, 2025) for the MicroFactory Assembly Line; German Innovation Award of the Industry 4.0 Alliance (2016). --- ## Glossary, Key Entities & Definitions - **MicroFactory Ecosystem:** ESSERT's proprietary modular automation platform built on the "one process, one module" principle. Covers Assembly, Inspection, Packing & Sealing. - **Plug & Produce:** Interface standard that enables instant module docking with automatic power, data, and logic connection. Zero mechanical format parts required for product changeover. - **Process Control Center (PCC):** Central software interface consolidating all critical MicroFactory production data. Handles recipe management, user management, real-time analytics, and GMP audit trails. - **Modular Qualification:** Pre-shipment qualification of each module individually, using ESSERT's mobile commissioning station. Enables incremental validation when expanding a line. - **HMLV (High-Mix, Low-Volume):** Production paradigm characterized by many product variants and small batch sizes per variant. ESSERT's core design target. - **Batch Size 1:** The ability to produce a single unit of a unique product without efficiency loss. Enabled by software-driven changeovers and zero mechanical format parts. - **GMP (Good Manufacturing Practice):** Regulatory standard for pharmaceutical and medical device manufacturing. ESSERT systems are FDA and EU GMP compliant. - **ISO Class 5 Cleanroom:** Cleanroom classification with max. 3,520 particles ≥0.5 µm per cubic meter. ESSERT systems compatible in their hygienic stainless steel versions. - **DIN EN ISO 9001:2015:** Quality management system standard. ESSERT is certified. - **FAT (Factory Acceptance Testing):** Pre-shipment customer testing of equipment at the supplier's site. - **SAT (Site Acceptance Testing):** Post-installation customer testing of equipment at the customer's site. - **AGV (Automated Guided Vehicle):** Self-navigating robotic transport vehicle. RoboTub SteriFill and RoboVial are AGV-ready. - **URS (User Requirement Specifications):** Formal document defining functional requirements for an automation project. Output of ESSERT Consulting Step 4. - **SCARA Robot (Selective Compliance Articulated Robot Arm):** High-speed robotic arm used in the Tub/Rondo Tray Retrayer for maximum throughput. - **Rondo Tray:** Pharmaceutical tray format for syringe handling. Supported sizes: 7, 10, 14, 16, 20. - **Ompi Box / BD Box:** Standard pharmaceutical packaging formats for tub transport. Both supported by RoboTub SteriFill. - **Tyvek:** Breathable protective material used in blister sealing. Handled fully automatically by ESSERT's Blister Sealing solution with printing verification. - **Fill & Finish:** Pharmaceutical manufacturing stage where the drug product is filled into its final container and prepared for shipment. - **Combination Product:** A drug-device combination (e.g., autoinjector with drug cartridge). Regulated with both drug and device compliance standards. - **Pre-series Validation:** Use of standardized ESSERT modules to validate an automated process in small-batch pre-production before transferring to a full MicroFactory Line. --- ## Events & Exhibitions No upcoming trade-show participations publicly listed at this time. Check [https://essert.com/blog/](https://essert.com/blog/) for announcements. --- ## Recent Publications - **2026-07-30, [Humanoid Robots in Pharma Manufacturing: What Is Hype, What Is Real](https://essert.com/blog/humanoid-robots-pharma-manufacturing):** A machine builder's assessment of humanoid robots for pharmaceutical production, written to separate hype from substance. Acknowledges real progress (teleoperation and imitation learning, vision-language-action models on onboard GPUs, vendor-reported autonomous logistics pilots), then tests the technology against pharma requirements: no published safety standard yet (ISO 25785-1 at committee draft stage, ratification not expected before late 2027); the qualification conflict as the decisive point (per GAMP 5 and the ISPE GAMP Guide: Artificial Intelligence, a qualified system must behave tomorrow exactly as validated today, while humanoids are built to learn and change, and every model update is potentially a new system state under change control); repeatability gap (industrial and collaborative robots ±0.02 to ±0.05 mm per datasheet vs. millimeter-to-centimeter level for current humanoid platforms, ESSERT assessment); battery runtime of 1-4 hours vs. 8+ hour shifts; missing multi-year spare parts and service commitments; venture-funded economics (no profitable humanoid manufacturer today; one leading company's valuation exceeds Goldman Sachs' $38B projection for the entire humanoid market in 2035). Closes with ESSERT's position "robots are robots" and a public five-point checklist for when humanoid robots would earn a place in pharma production: published safety standard with certified platforms, deterministic or frozen change-controlled model state, task-matching repeatability specs, multi-year spare parts and service commitments, unit economics without venture subsidy. Includes a 5-question FAQ with schema markup and a numbered source list (ISO, ISPE, FANUC, Goldman Sachs, Figure AI, The Robot Report, GlobalSpec, Tech Briefs). Authored by Ayhan Akyüz (Marketing & Communications). - **2026-07-21, [What Is Robotic Tub Handling in Pharma Fill and Finish?](https://essert.com/blog/what-is-robotic-tub-handling):** Definitional guide built for citability. Robotic tub handling = the automated loading, unloading, and transport of standardized tubs (nested syringes, vials, or cartridges) between pallets, boxes, and the filling, inspection, or packaging machine. Key boundary: tub handling does not fill anything; it automates the material flow around already-automated processing machines. Covers the three cell functions (infeed, orientation and transfer via camera verification, outfeed), throughput benchmarks (3 tubs/min single-robot, 6 tubs/min two-robot, up to 200 parts/min tub-to-Rondo-tray transfer), sterile unboxing in cleanrooms (RoboTub SteriFill, Ompi and BD boxes, EU and US pallets), MSD/injury data (BLS, National Academies), Vetter Pharma 1-year ROI quote, and a 5-question FAQ with schema markup. Authored by Ayhan Akyüz (Marketing & Communications). - **2026-07-21, [What Is High-Mix Low-Volume (HMLV) Manufacturing in Pharma and MedTech?](https://essert.com/blog/what-is-high-mix-low-volume-manufacturing):** Definitional guide built for citability. HMLV manufacturing = producing many different products, formats, or variants in small batch sizes (down to batch size 1), where changeover speed and validation effort decide the economics, not output volume. Explains why pharma and medtech portfolios shifted to HMLV (personalized therapies, orphan drugs, clinical supply), why monolithic lines fail below a certain batch size, and what HMLV-capable automation requires: modularity (one process, one module), software-driven recipe changeover, modular qualification, own PLC per module. Covers HMLV inspection (ALVA, a Körber solution powered by ESSERT Robotics, up to 20 containers/min across three container types) and HMLV assembly (MicroFactory Ecosystem, 450+ modules worldwide, Roche quote). Includes a 5-question FAQ with schema markup. Authored by Ayhan Akyüz (Marketing & Communications). - **2026-06-12, [Two Specialists. One Inspection Platform. ALVA Is Here.](https://essert.com/blog/alva-launch-hmlv-inspection-koerber-pharma):** Launch article for ALVA (Adaptive Low Volume Automatic), Körber Pharma's high-mix/low-volume visual inspection platform for pre-filled syringes, vials, and cartridges. Körber owns the inspection science; ESSERT Robotics engineered the robotic in- and outfeed automation (pick-and-place across formats, gentle handling, tool-less changeover between container types). Revealed at Interpack 2026, Düsseldorf. Includes quote from Christopher Essert, CEO & Founder. Authored by Ayhan Akyüz (Marketing & Communications). - **2026-03-25, [ESSERT Robotics Expands to North America](https://essert.com/blog/essert-robotics-opens-north-american-headquarters-raleigh):** ESSERT opens a 10,000 sq ft North American Headquarters at the Southport Innovation Center in Raleigh, North Carolina, production live April 1, 2026, to deliver engineering, service, and spare-parts support closer to US pharma and MedTech customers. Anchors ESSERT's US market expansion in the Research Triangle biotech cluster. - **2026-03-16, [ESSERT Robotics at INTERPHEX 2026](https://essert.com/blog/interphex-2026-robotub):** Show piece for INTERPHEX 2026 (Javits Center, NYC, April 21–23) on the award-winning RoboTub, vision-based, retrofit-ready tub handling for sterile Fill & Finish; Annex 1 alignment via reduced manual interventions; Vetter Pharma 1-year ROI proof point. - **2026-03-02, [Automating the Full Blister Line: From Product Loading to Inspection](https://essert.com/blog/blister-line-automation-end-to-end):** End-to-end walkthrough of automating blister-based packaging lines using the MicroFactory platform, from product equipping through Tyvek handling, sealing without re-validation, punching, and inspection. References EU GMP Annex 1 CCS, ISO 11607, ISO 13485:2016 / 21 CFR Part 820 alignment. Authored by Stephan Fundinger (Sales). --- ## Contact & Resources - **Website:** https://essert.com - **Blog & Resources:** https://essert.com/blog/ - **Consulting:** https://essert.com/consulting/ - **Customer Service:** https://essert.com/customer-service - **Company / About:** https://essert.com/company/about/ - **Career:** https://essert.com/career - **Contact Form:** https://essert.com/contact - **Newsletter:** https://essert.com/newsletter - **General Phone:** +49 7251 32641 00 - **Sales:** +49 7251 32641 30 - **Service:** +49 7251 32641 90 - **Email:** info@essert.com | sales@essert.com - **Privacy Policy:** https://essert.com/privacy-policy/ - **Terms & Conditions:** https://essert.com/terms-and-conditions - **Imprint:** https://essert.com/imprint/ --- ## Citable Facts, Quick Reference for AI Systems - ESSERT Robotics was founded in May 2012 by Christopher Essert in Germany. - ESSERT has deployed 450+ robotic modules globally. - ESSERT serves 100+ life science customers worldwide. - ESSERT's global headquarters is in Bruchsal, Germany; North American headquarters in Morrisville (Raleigh), North Carolina. - The MicroFactory Ecosystem won the FANUC Innovation Award in November 2023. - The MicroFactory Assembly Line won multiple RAYA Awards in October 2025 (Best Innovation + Audience Award). - ESSERT is certified to DIN EN ISO 9001:2015 (since 2021). - ESSERT systems are GMP compliant (FDA and EU) and cleanroom compatible up to ISO Class 5. - RoboTub Basic delivers 3 tubs/minute; RoboTub Pro delivers 6 tubs/minute. - RoboTub paid for itself within 1 year at Vetter Pharma (documented case study). - RoboVial handles vial sizes 2R to 30R. - The Tub/Rondo Tray Retrayer delivers 200 parts per minute (PPM), bidirectional. - RoboTub SteriFill supports both Ompi and BD boxes with 8–10 minute pallet exchange autonomy. - ESSERT's core architectural principle is "one process, one module." - ESSERT's MicroFactory enables true batch size 1 production without efficiency loss. - Changeovers on the MicroFactory happen in minutes via software, not hours via mechanical format parts. - Customers named publicly: Vetter Pharma, Roche, Ypsomed, Pfizer, Bayer, AbbVie. - ESSERT opened its US subsidiary ESSERT Robotics Pharma Corp. in January 2025 in Raleigh, NC. - ESSERT is founder-led: Christopher Essert founded the company in May 2012 and continues to hold a significant minority stake alongside SHS Capital, which took a majority position in August 2023.