NextGen Medical Solution

Efficient. Validatable. Future-proof

The innovative "NextGen Medical Solution" production cell has set a new standard in production for the medical sector. Working closely with a renowned OEM and our partners Hack and HB-Therm, we developed a cutting-edge solution that combines efficiency, quality and digitalisation. From the very beginning, the focus was on clear objectives: a comprehensive assessment of the total cost of ownership (TCO), a significantly shorter time to production, and exceptionally simple and intuitive usability.

Sustainable production

The production of caps for injector pens made from medical-grade PP results in a significantly reduced product carbon footprint thanks to innovative technology and optimised material selection.

Rapid validation

Intelligent assistance systems and a holistic approach ensure particularly fast and efficient qualification and validation.

Compact system design

The sophisticated overall design of the production cell reduces the space requirement by up to 25% compared to standard automated solutions.

Challenge

Developing a production cell for the medical technology industry placed extremely high demands on speed, precision and process reliability. In addition to rapid production readiness, it was particularly important to ensure reproducibility, complete traceability and reliable adherence to all process parameters. At the same time, consistent and transparent data documentation had to be guaranteed, and qualification and validation processes significantly accelerated. Another challenge was to optimally integrate all the components, from the machine to the peripheral equipment, arrange them in a compact layout, and intelligently interlink them via a central control system. The aim: a customised, future-proof solution enabling maximum transparency, efficiency and process stability in medical production.

Solution

This holistic approach enables an optimally integrated production cell with a high level of efficiency, quality, and transparency. The seamless integration of all peripheral devices results in a stable, continuous production process. Intelligent assistance systems continuously monitor and optimise processes, increase system availability, and ensure consistently high component quality. The compact automation concept also ensures maximum productivity in a minimal amount of space, even under clean-room conditions. The solution is complemented by intelligent energy and process optimisations that reduce resource consumption and increase productivity. Comprehensive interlinking, fast setup processes, and a preventive maintenance and spare parts concept combine to enable cost-effective, high-volume production with a low TCO.

The production cell is fully prepared for parametric approval and enables fast, reliable validation. The result: production that can be reproduced worldwide to the highest quality standards – while minimising time to market.

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Your ARBURG Contact

“The joint development of new technologies is focused and efficient since the expertise of each partner is taken into account from the very beginning. From day one, this collaboration combines all the strengths of each partner into a single, integrated and user-friendly cell. ”

Christopher Dickreiter, Senior Molding Engineer, Industrialisation, Sanofi S.A

Outlook

The production cell is fully integrated, digitally interlinked, and available today. Consistent use of all assistance and pilot functions provides optimum support for the entire process, from commissioning to series production. Centralised monitoring of all components ensures maximum transparency and control throughout the entire production process. This solution already offers a glimpse into the future of medical device manufacturing: integrated, efficient, fully automated and proactively maintained.

The project partners

ARBURG

ARBURG's all-electric production cell in "Medical Design" features highlights such as water-cooled direct drives, a fully integrated 6-axis robot and digitally integrated peripheral equipment. The GESTICA control system, with its intelligent and AI-driven functions, meets all the requirements for the injection moulding of future medical products.

Hack

High-precision 8-cavity injection mould with sliders and a full hot-runner needle-type shut-off nozzle – enhanced with integrated sensor technology.

Hack digital solutions

Innovative mould monitoring system with "moldlife sense" sensor technology fully integrated into the injection moulding machine.

HB-Therm

With the Thermo-6 temperature control unit, HB-Therm combines outstanding energy efficiency with reliable temperature and flow management – seamlessly integrated into the machine.