Pre-filled Syringe Packaging Line with Re-insertion Station
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Solution Overview
Problem
Current packaging lines for pre-filled syringes often result in waste due to trivial errors in secondary packaging, leading to the disposal of usable pharmaceutical products and devices, particularly during the coupling of needle safety devices, causing significant costs and inefficiency.
Innovation Solution
A packaging line with an automated process that includes a needle safety device (NSD) mounting station, visual inspection station, and re-insertion station to automatically identify and correct unfit assemblies, and re-integrate correctly assembled pre-filled syringes and needle safety devices back into the packaging line, reducing waste and maintaining product quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If strict validation is applied to secondary packaging, then packaging quality is improved, but product waste increases due to disposal of usable products
Solution Approach 1:
The packaging line is divided into multiple inspection stations that check different aspects separately: NSD coupling inspection, secondary packaging inspection, and labelling inspection. This segmentation allows identification of defects at specific stages without invalidating the entire product
Solution Approach 2:
The system performs preliminary inspections at multiple stages before final packaging completion. The NSD coupling inspection occurs before secondary packaging, and the re-insertion station provides preliminary correction opportunities, preventing premature disposal of usable products
2Manufacturing precision
If automated inspection is implemented, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The packaging line is designed as a multi-functional integrated system that performs NSD mounting, visual inspection, elimination of defective products, and re-insertion of correctable products. This universal approach consolidates multiple functions into one system, managing complexity through integration
Solution Approach 2:
The re-insertion station acts as an intermediary between the elimination station and the packaging line. It provides a buffer that allows correction of minor defects without complete line shutdown or product disposal, mediating between strict inspection and product salvation
3Reliability
If complete elimination of defective products is applied, then reliability is improved, but productivity decreases due to loss of usable products
Solution Approach 1:
The system selectively discards only those products with critical defects (improper NSD coupling) while recovering and re-inserting products with correctable minor defects. This selective approach maintains reliability by eliminating true failures while preserving productivity by salvaging usable products
Solution Approach 2:
The visual inspection station provides feedback to the control system, which then directs defective products to either elimination or re-insertion based on the type and severity of the defect. This feedback mechanism enables intelligent decision-making that balances reliability and productivity
Data Source
AI summary
A packaging line implemented for packaging a pre-filled syringe is disclosed having a NSD mounting station, a PFS delivery arrangement adapted to automatically deliver a pre-filled syringe to the NSD mounting station, and a NSD delivery arrangement adapted to automatically deliver a needle safety device to the NSD mounting station. The NSD mounting station is arranged to automatically assemble the needle safety device to the pre-filled syringe. A NSD visual inspection station is adapted to automatically identify a pre-filled syringe with an unfit needle safety device and to automatically eliminate the identified pre-filled syringe from the packaging line. A re-insertion station is further provided to receive a pre-filled syringe with a needle safety device and to automatically feed the received pre-filled syringe, preferably from a rejected secondary packaging, back into the packaging line, after the NSD mounting station and before the NSD visual inspection station.