Sales rise by 10.2 percent in 2015 to reach 1.3 billion euros
Order intake is 14.5 percent higher than 2015
Executive board expects moderate growth for fiscal 2016
Complete lines and Industry 4.0 solutions are strategic areas of growth
Waiblingen, Germany – Bosch Packaging Technology increased its sales from 1.18 billion euros in 2014 to 1.3 billion in 2015, representing nominal sales growth of 10.2 percent (3.1 percent when adjusted for currency effects). This puts the machine manufacturer – one of the leading providers of processing and packaging technology solutions – ahead of its competitors. According to industry association VDMA, the German manufacturers were able to achieve nominal sales growth of just 2.8 percent on average. Order intake at the Bosch division also rose over the same period, increasing by 14.5 percent in nominal terms from 1.23 to 1.4 billion euros. Adjusted for currency effects, this corresponds to an increase of 7.2 percent. As of the end of the year, Bosch Packaging Technology employed some 6,200 associates at more than 30 locations worldwide. “We are satisfied with our double-digit rise in sales, particularly given the modest growth of the sector as a whole. In 2015, we were again able to increase our market share,” summarizes Friedbert Klefenz, president of Bosch Packaging Technology. He anticipates moderate growth for fiscal 2016.
Strongest growth in the Asia-Pacific region Sales in Europe declined slightly in 2015, ultimately accounting for 37 percent of total sales. In North America, sales grew by almost 18 percent – remarkable given the generally stagnant situation in the machine manufacturing market. Overall, North America now accounts for 27 percent of total sales. Latin America saw sales growth of almost 25 percent. At the continental level, Bosch achieved its greatest growth – somewhat above 27 percent – in Asia-Pacific and Africa. In total, Bosch Packaging Technology generated some 90 percent of its sales outside Germany in 2015. Emerging markets are thereby playing an increasingly important role.
Acquisition of three companies in the food sector Part of Bosch Packaging Technology's growth strategy is to strengthen its position through strategic acquisitions. In addition to founding a joint venture with the Indian company Klenzaids in 2015 (focus on pharmaceuticals), last year the company acquired three further enterprises in food: Osgood Industries Inc. in Oldsmar, Florida at the end of May 2015 and, in December, the two sister companies Kliklok-Woodman Corporation, headquartered in Decatur, Georgia (U.S.), and Kliklok International Ltd. based in Bristol, England. Bosch Packaging Technology is thereby continuing to expand its position in the pharma, food, and confectionery sectors and, above all, strengthens its expertise as a complete solution provider. The companies acquired in 2015 have not been consolidated on the balance sheet for that year.
Moderate growth expected in 2016 The overall rather modest start to 2016 coupled with the high volume of orders from last year leads Klefenz to anticipate moderate single-digit growth for the current fiscal year. To drive growth, Bosch Packaging Technology plans to further expand its line and system competence and develop solutions for the connected production of the future.
Complete solutions from a single source At Bosch Packaging Technology, a key topic for the future remains line and system competence. Here, Bosch not only views itself as n a provider of the entire production line, from processing technology to the finished packaged product, including services. Instead, the company is taking the approach a step further and looking to turnkey projects, which it sees as offering great potential, especially outside Europe. In these projects, Bosch assumes responsibility for everything from planning of material and personnel, building technology, and cleanrooms to the production facilities themselves, thereby providing customers with complete solutions from a single source. Projects have already been successfully implemented with customers from the pharmaceutical industry in Latin America, the Middle East, and Russia.
Industry 4.0: applying the Bosch Group`s know-how to target industries Industry 4.0 is another driver of growth. The modern factory is smart and connected, linking traditional manufacturing with sensors, software, and services. Bosch Packaging Technology works with its customers on pilot projects aimed at developing needs-oriented solutions. In doing so, the company can draw on the Bosch Group's many years of experience. “Whenever it is a question of connectivity, we benefit from the Bosch Group's expertise as a leading user and leading provider in this area. We will be launching a whole range of pilot projects in 2016 in order to tailor Bosch's existing software solutions to the needs of our customers in our target industries pharmaceuticals and food,” says Klefenz. One such solution already employed by customers all over the world is Bosch's Track & Trace software.
For instance, to give one example: in 2015, Bosch Packaging Technology and Hikma Pharmaceuticals in Jordan and Saudi Arabia implemented Track & Trace projects for pharmaceuticals. Using Bosch technology, the company prints and verifies up to 400 cartons per minute, and is capable of printing serial numbers, 1D and 2D codes, batch data, and expiry dates on the cartons. Bosch's new software ensures that the software and machines within the process are reliably connected. The various packaging lines can then be monitored from a central office. Thanks to the solution, Hikma is also able to export the data to an external database, for instance that of a regulatory authority. In 2016, other customers in the U.S., the UK, and Austria will be equipping their production facilities with Track & Trace systems made by Bosch.
Contact person for press inquiries: Christin Pönisch, Phone: +49 711 811-58502
Symposium: lectures, discussions and new technologies
Pharmaceutical line competence: Bosch showcases new solutions
300 participants from all over the world
Crailsheim, Germany – Connected industry and its opportunities for pharmaceutical production – 300 international pharma experts discussed this topic from 10 to 11 May in Crailsheim, Germany. “Pharmatag”, hosted by the division Packaging Technology, already took place for the eighth time. With 50 percent more guests from the pharmaceutical, biopharmaceutical and process technology industries, the symposium achieved record attendance. “Pharmatag 2016 offered the 300 participants from all over the world a versatile mix of lectures, podium discussion and new technologies,” said Joachim Brenner, general manager at Bosch Packaging Technology in Crailsheim. “The growing number of participants of this triannual event shows that Bosch Packaging Technology plays a leading role in the pharmaceutical industry and the high customer demand for events like this.”
Focus on pharmaceutical line competence On day one, the guests of Pharmatag had the opportunity to look behind the scenes of the Crailsheim production facility and to receive first-hand information about Bosch's pharmaceutical line competence as well as current portfolio expansions. A special highlight was the launch of the new ALF 5000 filling and closing machine for ampoules and injection bottles. Apart from an output of 600 containers per minute, the machine features high flexibility and process safety.
The second day with lectures and a podium discussion was opened by Friedbert Klefenz, President of Bosch Packaging Technology. In his key note speech, Prof. Thomas Bauernhansl, head of the Fraunhofer Institute for Manufacturing Engineering and Automation, and the Institute of Industrial Manufacturing and Management at the University of Stuttgart, gave insights into the opportunities of industry 4.0, as well as an outlook on the future of pharmaceutical production.
Representatives of the companies AbbVie, Eli Lilly, NNE Pharmaplan, Roche Diagnostics and Vetter Pharma reported on unusual projects, current challenges and future trends, such as filling of highly potent pharmaceuticals and innovative approaches for the development of parenteral dosage forms. The subsequent podium discussion addressed quality, flexibility and industry 4.0 in pharmaceutical manufacturing. Claudia Petersen, Global Director Business Development at Gerresheimer, led through the program.
CPI software for connected serialization Apart from numerous filling machines and lines for liquid pharmaceuticals, the participants also received information about exterior washing of vials and ampoules (RAN 3080), the combination of visual inspection technology and leak detection (AIM 3000), matching downstream equipment (RIL 3010), as well as special customer projects. Secondary packaging and serialization solutions completed the presentation of Bosch's pharmaceutical line competence.
Moreover, Bosch showcased further industry 4.0 application possibilities for the pharmaceutical industry. Combined with the CPI software from Bosch, Track & Trace solutions can be integrated into the company IT in a multi-level process. This way, manufacturers are not only able to process the entire order management; they also control both import and export of the serial numbers. All relevant data is available in the company network and can be transferred to regulatory or company-owned databases according to regulatory requirements.
A further important part of Bosch's line competence consists in after-sales services, which support customers in flexibly adapting their existing equipment to future market requirements.
General manager Joachim Brenner was satisfied with the outcome of Pharmatag 2016, “Not long ago we hosted the Meet & Match event of BIOPRO Baden-Württemberg, and for the last two days we welcomed representatives of the leading international pharmaceutical companies. This shows the importance of the Bosch Packaging Technology site in Crailsheim for the industry – regionally and internationally.”
Contact person for press inquiries: Christin Poenisch phone: +49 711 811-58502
Robots without safety guards: people and machines working hand in hand
The APAS family continues to grow: collaborative robotics are on the rise
The APAS workstation: intelligently connected workplace with integrated robot
IT Shopfloor Solutions: scalable automation system for the production and logistics chain
Stuttgart/Hannover – At the 2016 Hannover Messe, Bosch presents combined hard- and software solutions for the flexible, networked factories of tomorrow. These Connected Shopfloor Solutions are the essential link at the heart of Industry 4.0, and are already in use today, at Bosch and elsewhere: mobile assistance systems work side by side with their human operators and without the need for safety fences, while modular automation systems analyze, report on and control a wide range of production processes. Yet people remain at the center of it all: “Given the spectrum of work processes in today’s manufacturing, people are now needed more than ever as decision-makers and overseers,” explains Volker Hartmann, Deputy Vice President Business Unit Assembly Systems and Special Machinery at Bosch. “Our robots are there to free human operators from tasks that are potentially unsafe, overly simple and monotonous, or ergonomically challenging.”
A fresh face: the APAS workstation Accordingly, when it comes to developing new solutions, Bosch consistently adopts the perspective of the operator. The most recent example of this user-centered automation: the APAS workstation, which will first be unveiled in Hannover. The APAS is the first standardized workstation to offer direct and safe man-machine collaboration. Offering a truly versatile solution, it integrates a collaborative robot kinematics system (APAS safekin) and further automation components. The APAS workstation takes advantage of new collaborative models that place the focus squarely on the operator. Successfully combining human beings’ inimitable problem-solving skills with the tirelessness and precision offered by robots, they deliver more efficient processes and higher productivity. The integrated robot kinematics system supports the operator, lending him or her a “third hand.” Yet the operator remains the focus, and can enjoy an individually tailored, ergonomically optimized work setting: the worktable height and lighting automatically adjust to the operator, while the adjustable see-through digital display allows them to see all essential production data at a glance. The flexible APAS workstation can be used with or without an integrated robot, and can network with further assistance systems as needed.
APAS safekin: seamless integration The robot kinematics system, dubbed APAS safekin, can also be used independently of the mobile APAS base or an APAS workstation – then recommended as a fixed installation in a dedication production segment. The new automation component can be easily integrated into IEC61131 applications that conform to the standard international norm for programming languages. This allows projects to be rapidly implemented, humans and machines to work together safely, and existing facilities to be readily upgraded. No robotics programming is needed for the creation of individual robot movements; the jobs can easily be prepared, configured and managed using the graphic interface.
APAS family: constantly growing In addition to the newly introduced APAS workstation, the APAS family includes three other mobile, collaborative assistance systems. The APAS inspector is equipped with a high-resolution, high-speed camera and innovative 3D mapping technologies. Thanks to interchangeable testing modules, the station can be used in various production contexts – like high-precision surface inspections or completeness testing. In turn, the APAS flexpress is the candidate of choice for highly flexible, high-precision joining – which, by the way, is one of the most common work steps in production lines. Its integrated safety features ensure that it can seamlessly support its human operator. The same is true for the APAS assistant, which features a six-axis industrial robotic arm, sensitive three-finger gripper, and 3D camera system. The APAS assistant was the first assistance system to be certified by the German occupational health and safety agency. Thanks to its specially designed sensor skin, it can collaborate directly and contact-free with its human operator without the need for further precautions.
As an available option, the APAS speedswitch can be set to vary the APAS assistant’s operating speed, depending on whether or not human beings are nearby. The extended vicinity is monitored by the speedswitch interface and, provided no employees are nearby, the kinematics system operates at maximum speed. If someone approaches the APAS assistant, it automatically drops to a safe speed. The result: increased productivity without sacrificing workplace safety.
IT Shopfloor Solutions Meanwhile, behind the scenes Bosch’s IT Shopfloor Solutions deliver safety, flexibility and transparency throughout the production chain. For more than 15 years now, the modular and scalable software solutions have been continually refined within the Bosch Group and used to manage hundreds of production facilities around the globe. Thanks to a broad range of software modules for Shopfloor Management, machinery can be networked regardless of the product or brand, product defects and the need for maintenance can be recognized early on, and production data can be analyzed in real-time. Thanks to intuitive, graphic tools, operators can more quickly recognize critical situations, more easily localize errors, and more promptly respond to them. The focus is on user-friendliness, and here, too, the collaboration of man and machine reduces complexity. Further, maintenance-relevant parameters can be viewed at any time on a wide range of devices. Depending on the application, a central dashboard can also gather all essential information at a glance. All IT Shopfloor Solutions are based on a shared control platform and standardized software concept, helping to ensure that work processes can be made not only faster and more efficient, but also significantly more flexible and operator-friendly.
Preheater reduces heating energy consumption by up to 30 percent
Modularization leads to shorter delivery times
Bosch Packaging Technology has developed a new generation of pure media systems with optimized performance and energy efficiency, including pure steam generators and distillation units for the production of sterile, pyrogen-free pure steam or WFI (water for injection). “We contribute to a significantly more efficient production of pure media and to more sustainability in the pharmaceutical industry,” says Dr John Medina, sales director at the Bosch subsidiary Pharmatec. For instance, the preheater reduces heating energy consumption by up to 30 percent.
Focus on energy efficiency and sustainability Pure steam and WFI are key components of pharmaceutical production. While WFI is predominantly needed for the production of infusion and injection solutions, pure steam is mainly used for sterilizing equipment components like preparation vessels, piping systems and filling machines. In addition, pure steam is employed for the humidification of air in cleanrooms.
Bosch delivers the new distillation units with a preheater by default. From the second column onwards, it uses pure steam from the previous column to preheat the feed water. As a result, heating energy demand is significantly reduced. For pure steam generators, a preheater is available as an option. It is fed with condensate from the heating steam. Using this stored energy leads to reduced heating steam consumption.
High thermal efficiency and reduced blowdown Evaporation is a basic operation in the production of pure steam and WFI. The equipment’s evaporator operates according to the proven natural circulation principle. The water, which is fed for evaporation, continually circulates between the evaporation chamber and the heat exchanger. A high thermal transfer enables the system to be heated up smoothly without causing temperature stress for the evaporator. This process only needs electrical energy or heating steam; no further process steps or functional modules such as a compressor are required.
“The new, compact design of the evaporator contributes to optimal thermal use of heating energy, leading to high yields and low operating costs”, explains Medina. “Since the production of pure steam and WFI is particularly energy-intensive, improvements in efficiency play an important role in sustainability and climate protection.” The geometry of both evaporators and condensers has been optimized for the new product range. For instance, Bosch adjusted the evaporator’s diameter as well as number and formation of the heating pipes. Subsequently, the machines can achieve 20 percent higher performance rates compared to previous models. Bosch also succeeded in reducing the amount of water loss, which results from the disposal of endotoxins (blowdown) in the feed water, from between five and eight to no more than four percent.
From 100 to 7,500 kilograms per hour With these new developments, Bosch has streamlined the product range, compiling a consistent set of machines. The number of different sizes was reduced from eleven to six pure steam generators and from fourteen to ten distillation units. “Customers profit from shorter delivery times, lower acquisition costs due to a higher degree of standardization and modularization,” says Medina. The series now encompasses a performance range of 100 to 7,500 kilograms per hour. In order to enable quick set-up, feed water pumps with frequency regulation are used for all sizes. The equipment can be further adapted to the respective operating conditions.
Contact: Klaus Schreiber phone: +49 351 28278-833
Contact person for press inquiries: Christin Poenisch phone: +49 711 811-58502