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Robots in pharmaceutical manufacturing
10 January 2023
Pharmaceutical manufacturers require state-of-the-art, smart production equipment to meet the changing needs of the industry. Mass-produced pharmaceutical recipes are becoming a thing of the past, as demand for product, aligned with changing consumer behaviours is driving mass customisation. Intolerances, allergies and the changing dynamics of infectious conditions mean that one size no longer fits all.
Maintaining the best quality product output, mitigating waste and satisfying demand are crucial to pharmaceutical manufacturers. Robots and automation are integrating into solutions that enable the successful and efficient delivery of products across a diverse, domestic market that is being challenged by international competition - reduced cost of production enables the delivery of cost-efficient products to market.
Robot technology from KUKA can be employed right along the process chain, from API recipe testing and ingredient measuring to packaging product in clean room facilities. Such robot models have been specifically adapted to operate under the strictest of hygienic conditions, manufactured of stainless steel and safe for utilisation in direct contact with pharmaceutical substances.
A variety of robot models, from mobile robots to collaborative medical iterations are available and are being used, today, to assist in the management of complex and sometimes time-consuming and complex tasks that require agility and resilience around the clock.
COVID-19 saw an explosion in the adoption of innovative, automated solutions to meet urgent market demands. The management of an increase in complex and varied laboratory-based tasks, coupled with the challenges presented by social distancing meant robotics, was, in many cases, the natural fit, to sustain increased levels of activity, that couldn’t be undertaken by humans in the same timeframes and at such high volumes.
New levels of laboratory testing excellence were achieved thanks to robotic and digital technologies. One such solution, a mobile robot scientist, developed by Liverpool University, conducted 688 experiments over eight days, working for 172 out of 192 hours. In doing so, it made 319 moves, completed 6,500 manipulations, and travelled a total distance of 2.17km.
Automated tasks within the pharmaceutical industry can include weighing out solids or dispensing liquid. The accurate and repeatable characteristics of modern-day robotic technology mean the dexterity of task execution is far superior to that which can be undertaken by humans and can be sustained, without interruption over long periods of time.
Traceability, once a product leaves a facility is also a vital consideration in fast-paced environments, such as pharmaceuticals. Having the appropriate coding and marking solutions in place, often delivered by automated robot methods and supported by integrated vision inspection systems, ensures that recalls can be quickly and efficiently managed. Global Trade Item Numbers (GTIN) applied by robots can be done so at speed and across high product volumes, ensuring compliance.
Technological advancements, such as robotics and automated processes are enabling the pharmaceutical industry to serve more people than ever and advance medicinal research. As the needs of the industry become ever more challenging, and intelligent, a digital workforce is just around the corner.
The use of robotics and automation, outside of what are considered conventional applications, is increasing, aligned with rapidly changing manufacturing dynamics and assembly lines. More recently, there have been many changes in the medical market that have accelerated the use of automation and robotics, that include falling margins, the ever increasing cost of cleanroom real estate, and overseas competition.
Mergers and acquisitions among many of the world’s leading manufacturers have also increased internal competition for new product lines making competitiveness ever more important. In short, technologies are helping pharmaceutical manufacturers go further and faster.
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