Bio-Rad, a leading pharmaceutical company, needed a fully automated labelling system that met specific requirements in terms of efficiency and reduced physical effort during machine loading.
Labelpack designed and implemented a customised solution that lifts, separates and serially labels glass tubes, fragile laboratory material. The system optimises productivity and lowers operational costs.
The success of the implementation led Bio-Rad to extend the automation to other stages of the production process, establishing a long-term partnership with us.
Initially, the process required an operator to manually lift 30 kg boxes containing fragile glass tubes to load them onto a labelling machine. Due to the delicate nature of the product and its significant weight, the operation required considerable physical effort and frequent operational breaks.
Under these conditions, Bio-Rad needed a loading system that met the following requirements:
- safe handling of a fragile product;
- automatic singularisation of test tubes;
- quality control of labelling with automatic machine stop in case of non-compliance;
- increased production capacity.
Bio-Rad relied on us to explore different possibilities and create together the optimal solution.
Specialised consultancy, analysis, ongoing support and technical inspections enabled us to identify the company’s operational needs. This approach allowed us to outline the specific problems to be solved and to start developing a technological solution to meet these requirements.
The design of the machine we realised includes a prototype loading system and a highly versatile labelling solution. The custom-designed machine meets Bio-Rad’s specific requirements.
The result is a machine of small dimensions, under 3 metres in length, capable of automatically handling delicate glass tubes, lifting and loading them onto a specially developed structure for singularization and labelling.
To meet the company’s needs, we added special technical solutions to the MASTER WR system for the cleaning of the various moving parts. In addition, the customised loading system we developed is ergonomic and user-friendly, ideal for easily handling the Bio-Rad tube racks.
After running the FAT in Labelpack, we installed the machine at Bio-Rad’s site in Belgium, with training sessions and final refinements conducted together with the operators during the production simulation, optimising utilisation.
Thanks to the implementation of the MASTER WR system, the company was able to optimise the consumption of compressed air and electricity during the product waiting and stand-by phases. In addition, the system has improved machine status monitoring, thanks to connection functions that enable remote assistance, workflow analysis and activation of predictive support.
The MASTER WR system with autoloader fully responded to Bio-Rad’s needs, resolving operational issues. Currently, the machine operates with high performance:
- Average speed of 18,000 pieces per hour;
- Production almost tripled.
The result has been an increase in productivity and quality, with an automated and continuous process that has eliminated physical and mental stress for operators, streamlining operations and reducing personnel costs.
The excellent relationship established with Bio-Rad during the collaboration led to the renewal for following projects, aimed at extending the use of automated solutions to other stages of the production process.
After testing our system, Bio-Rad also chose to entrust us with the automation of critical areas, such as those with stringent requirements, like the cold chain.
At the same time, we guarantee continuous support even after delivery, performing regular maintenance to prolong the machine’s longevity and keep it efficient.
Thanks to our design and service expertise, Bio-Rad has a durable, high-performance solution on its hands, that can significantly improve business processes, contributing to innovation and optimisation of work.
