For this client, STERISYS combined the FlexyBot II and  FlexyBot III to a customized handling solution for a sterilization plant. 

The customer is an international pharmaceutical CDMO (Contract Development Manufacturing Organisations). They operate different filling lines for prefilled syringes. The purpose is to install an automated terminal sterilization unit on two filling lines to meet the ever-increasing market demand for sterilized prefilled syringes. Not only the sterilization, but also the removal of the syringes from the pallet box and the insertion of the sterilized syringes into the pallet boxes should be automated. They work with pallet boxes with divider sheets.

STERISYS' solution involves the automated loading and unloading of sterilization racks. Through close collaboration with a partner responsible for constructing the hot air sterilization system, we developed a complete customized handling solution.

In addition, the FlexyBot Vision Gripper is integrated, which provides the camera-guided gripping and is also used for the process control system. In detail, the nest is photographed before it is taken out of the tub. This image runs through an image processing system, which detects whether the position of the nest is correct. If not, the gripper adjusts itself accordingly, so that safe gripping is guaranteed. The system also checks whether the tub is really empty after the nest has been removed. This check is also performed at the end, before the nest is placed in the tub to avoid any non-sterile syringe to stay in and be delivered with sterile syringes for the safety of the patients.