Compact, mobile filling unit automates pharmaceutical bottle handling

Previously, bottles were filled manually, with operators positioning each bottle beneath the filling needle, triggering the filling cycle and transferring the filled bottles to a belt conveyor for capping and labelling. This process involved considerable repetitive handling, placed strain on operators and was frequently interrupted.

The challenge was to develop a compact, mobile system capable of buffering a large number of empty bottles and automating the filling process, allowing the unit to operate autonomously for a defined period without continuous manual intervention.

Automated filling with integrated buffering

The solution combines mk's Versaflex A08 flat top chain conveyor with a DT-P 2040 rotary table, creating a modular filling system that can be moved between production areas and integrated into existing manufacturing lines.

The 750 mm diameter rotary table provides a buffer for empty bottles, enabling the system to continue feeding the filling station without requiring operators to position every bottle individually. Empty bottles are loaded onto the table in a single operation using a sliding platform. The conveyor then automatically transfers them towards the filling station.

At the filling position, three bottles are precisely located and stopped simultaneously. An integrated lifting device automatically lowers the customer's filling needles into the bottles, enabling a repeatable filling sequence. Once filling is complete, the bottles are released and conveyed onwards to the customer's existing conveying system for subsequent capping and labelling operations.

This automated sequence reduces the need for manual handling at the filling station and helps maintain a consistent process throughout operation.

Designed for flexibility and easy integration

A key consideration in the design was the ability to accommodate the customer's existing equipment while keeping the overall footprint compact. The system incorporates a central controller, which allows the customer's pumps and operating unit to be connected directly. Dedicated space for the pumps is integrated into the machine frame, while the operating unit is mounted on a side panel in an ergonomically accessible position.

The mobile design allows the filling unit to be repositioned and used on different production lines, providing flexibility as manufacturing requirements change. Its compact construction also supports integration into existing production environments without the need for a complete line redesign.

Improving efficiency through modular automation

By combining automated bottle handling, integrated buffering and precise positioning, the mk solution addresses several challenges associated with manual filling processes. Operators no longer need to position each bottle individually or trigger every filling cycle, reducing repetitive tasks and associated ergonomic demands.

The buffer function also enables the system to run autonomously for a defined period, helping to reduce interruptions and allowing operators to focus on other production activities. Automated positioning and a repeatable filling sequence support process reliability, while the modular conveyor-based design offers flexibility for future production needs.

The project demonstrates how modular conveyor technology can be used to automate a specific stage of a manufacturing process, improving operational efficiency while working within the constraints of an existing production environment.