Independent platform for knowledge and experience exchange
Keynote speaker: Prof. Dr. Dr. Franz-Josef Radermacher
Exhibition of product innovations in pharmaceutical technology
Crailsheim – On May 14 and 15, 2013, Bosch Packaging Technology held its 7th “Crailsheimer Pharmatag”. The international symposium for sterile filling offered pharmaceutical experts and opinion leaders an independent platform for interdisciplinary knowledge and experience exchange. “We spent two successful and exciting days with guests from all over the world. With its extensive program and interesting topics, the Crailsheimer Pharmatag once again was the perfect event to discuss current trends with colleagues from the industry,” said Joachim Brenner, site manager in Crailsheim. With a facility tour on the first day, the approximately 250 visitors had the opportunity to look behind the scenes and to celebrate the inauguration of the new assembly hall. Day one ended with an entertaining dinner event for all participants.
Field reports and expert discussions The second day traditionally focused on presentations and panel discussions. Bosch was delighted to introduce Prof. Dr. Dr. Franz Josef Radermacher, head of the Research Institute for Applied Knowledge Processing in Ulm, as keynote speaker. He opened the morning session with his lecture on current and future pharmaceutical trends. During the following presentations, the audience learned about the role of research and development in the pharmaceutical manufacturing process, and new challenges in aseptic filling. Speakers included representatives of Boehringer Ingelheim, Ypsomed, AbbVie, Lilly, Sartorius Stedim Biotech, and the Fraunhofer Institute in Braunschweig.
Panel discussion and product highlights Friedbert Klefenz, president of Bosch Packaging Technology, and Joachim Brenner, site manager in Crailsheim, discussed current production trends such as contract manufacturing, small batch sizes, ready-to-use containers, 100 percent in-process control and lean production with participants. Charlotte Enghave Fruergaard, PhD, from NNE Pharmaplan, led through the program. A further highlight of this year’s Pharmatag was the presentation of new products from Bosch. Participants gained insights into the entire product portfolio of process and packaging technology for solid and liquid pharmaceuticals.
The new filling and closing machine MLF 5088 was particularly highlighted among the exhibits. It offers an output of up to 400 vials per minute with integrated 100 percent in-process control (IPC). The combined filling station with eight dosing heads is suited for restricted access barrier systems (RABS) as well as isolators, and containment systems for toxic products.
System competence for solid and liquid pharmaceuticals With the integration of Eisai Machinery, Bosch has substantially extended its inspection portfolio. The semi-automatic VIS 200 is used for the inspection of empty and filled vials from two to 200 milliliters. It examines containers for foreign particles in liquid or lyophilized pharmaceuticals, as well as cosmetic defects such as glass cracks or missing caps. Furthermore, Bosch has developed the KKX 3900, a new inspection unit for capsules based on soft x-ray technology.
Bosch also showcased the Fast Air Lock ISS 1000 for fast and contamination-free transfer of pharmaceutical equipment into and out of isolators, and the standardized CIP/SIP (cleaning and sterilization in place) compact unit for pharmaceutical containers, vessels and small production accessories. The laboratory machine Solidlab 2 combines three process modules in one single machine: powder mixing, granulating and coating of pharmaceutical pellets and tablets. The exhibition was rounded out by a comprehensive range of services, including the new mobile conference system Mavus, and a mobile data collection system for the evaluation of Overall Equipment Effectiveness (OEE).
Dr. Marc-Olivier Demaurex, president of Bosch Packaging Technology SA, to retire
Frank Souyris appointed as general manager
Romanel / Waiblingen – Dr. Marc-Olivier Demaurex, president at Bosch Packaging Technology SA in Romanel, Switzerland, is to retire at the end of April. Meanwhile, Frank Souyris has been appointed general manager for the robotics unit. Dr. Demaurex has led Bosch’s work in the automation sector for many years, helping to make the company’s Delta robots one of the leading automation solutions for the packaging industry. Mr. Souyris previously collaborated with Dr. Demaurex during his tenure as sales manager with Demaurex SA. Both have been working together recently to ensure a smooth transition and handover of responsibilities.
Delta robots – revolution in technology Dr. Demaurex joined Bosch when Demaurex SA, the Swiss company he founded, was acquired in 2004. Under his leadership, Demaurex SA first commercialized the Delta robot and held the exclusive patent for the technology until 2007. The principal of parallel kinematic Delta robots originated at the Swiss École Polytechnique Fédérale de Lausanne where a team led by Professor Reymond Clavel completed the first concepts and developed the primary industrial units. The Delta robot, which was the first to make high-speed vision guided picking for lightweight products available to the manufacturing sector, accelerated packaging lines and increased efficiencies through its unique design of three translational degrees and one rotational degree of freedom.
Delta robots – drivers for innovation Quickly grasping how this new automation solution could revolutionize the packaging industry thanks to its speed, versatility and accuracy, Dr. Demaurex extended its use from initial applications in chocolate packing factories to a broad range of applications worldwide, such as confectionery, non-food and secondary packaging.
“It’s incredible to see how rapidly the Delta robot has been adopted by manufacturers around the world, keen to harness its speed and precision,” said Dr. Demaurex. “I know that under Frank’s stewardship, Bosch will continue to refine this unique robotic technology and drive innovation in this sector, enabling manufacturers to increase their line efficiencies, drive competitive advantage and subsequently compete more strongly against their rivals.”
Future looks bright for Delta robots After graduating from the Institut National des Sciences Appliquées de Lyon in 1988, Mr. Souyris joined Demaurex SA (now Bosch Packaging Technology SA) as sales engineer. Working in the company at the outset provided him with the unique opportunity to play a strong role in the development of the Delta parallel kinematic robot. In the following years he was in charge of promoting robotic solutions in the French market, until in 1994 he took over the sales manager role, responsible for overall sales.
Since 2001, Mr. Souyris has held positions of chief operating officer (COO) and general manager in various companies, prior to returning to the team and taking up the reins as general manager at Bosch Packaging Technology SA on 1 March 2013.
“It is very exciting to be back in the company, even though many things have changed, and to be back in the rapidly evolving area of robotics for the packaging sector,” said Mr. Souyris on his return. “Let’s build on the momentum cultivated over recent years and push ahead in the development of robotic technology by penetrating the market further and cementing our leading position. I can still see the excitement in the eyes of the people involved in robotic applications for the packaging sector. It is this energy that we will continue to foster and promote as we look to serve our customers with opportunities to increase their competitive advantage.”
Plug and play approach and intuitive HMI for ease of use
Use of standardized components lowers the requirement for spare parts
Bosch Packaging Technology launches Gemini 4, a new Delta robot hardware platform and software controller. With increased speed and lower changeover time resulting in higher productivity, the platform allows manufacturers to reduce the Total Cost of Ownership (TCO) of their automated production lines. The hardware component of Gemini 4 has a streamlined architecture and integrates standardized industry equipment from German automation specialists Bosch Rexroth and Beckhoff. Operators are now able to run up to eight Delta robots and sixteen conveyors through the simplified Gemini 4 controller for gains in efficiency.
The streamlined design of the Gemini 4 controller and its software are optimized for the control of Delta robots, helping to increase acceleration and pick rates. This enables manufacturers to enhance accuracy and raise their production line speeds by up to 25 percent (product dependent), while maintaining gentle product handling, process reliability and quality.
In the past, manufacturers with Delta robots seeking to boost output would use a multi-picking technique with special picking heads to increase the number of products handled by the robots. This approach required lengthy changeovers whenever products or pack styles were changed, as a new head would have to be applied. With the new Gemini 4 controller and the gains in speed inherent to the new hardware, manufacturers now no longer need to use multi-picking heads to enhance performance. Regardless of the pack size or style, the same head is being used, eliminating the downtime for changeovers. These overall gains in productivity mean a reduction in the cost per pick. In addition, due to its higher pick density in comparison with previous versions, the new controller has a smaller footprint, leaving room for more robots.
An additional benefit of the Gemini 4 is its ease of use, both in set up and operation. Its Human Machine Interface (HMI) can store instructions for the production of multiple products, which speeds initial set up and reduces changeover time from twenty minutes to one minute (including gripper changeover). The software utilizes a user interface similar to previous Gemini iterations, ensuring operators familiar with the system can work with it needing only minimal training. This hardware platform is also used with other Bosch machines, allowing customers with more than one Bosch solution reduce their spare parts inventory as the same components can be used across multiple controllers. This results in lower fixed capital and shorter training periods, reducing TCO.
“The Gemini 4 boosts standards in the field of Delta robot control,” said Roy Fraser, product manager Robotics, Bosch Packaging Technology. Innovations in the automation of the manufacturing process have driven down the TCO, allowing multinational brand owners and local enterprises alike to increase productivity and improve competitiveness.”
Total investment of 55 million CNY (6.6 million Euros)
From 14 to 500 associates, striving for continuous boosting business
A compounded annual growth rate of over 40 percent in recent five years
Hangzhou / Waiblingen – As one of the leading suppliers of process and packaging technology, Bosch Packaging Technology in China has completed its third plant expansion in Hangzhou in March 2013. The total investment of the plant extension is 55 million CNY (6.6 million Euros). The new building area is enlarged with additional 8,000 square meters to reach an overall building area of 24,400 square meters and a production area of 13,600 square meters. The expansion will be mainly for pharmaceutical business production, aiming to further meet increasing local market needs.
“Over the past five years, the company has achieved a compounded annual growth rate of over 40 percent. And we gear ourselves well to prepare for continuous growth. As an example, in this new facility, we have built a new laboratory for our pharmaceutical business to serve our customers better with a ‘One Stop Shopping’”, said Chee Kian Kang, general manager of Bosch Packaging Technology China.
Bosch Packaging Technology witnessed a healthy and promising business development since 2001, marked by a strong commitment to the local market. From a rental factory with 14 associates in 2001, Bosch Packaging Technology Hangzhou has grown to a company with 500 associates by the end of 2012. “I am fully convinced that the additional investment in Hangzhou will enable the company to strengthen its competitiveness in the Chinese packaging market”, said Friedbert Klefenz, president of Bosch Packaging Technology.
The sustainable environment in the Chinese market further grants Bosch Packaging Technology firmer confidence in the future development. In addition to the expansion in Hangzhou, Bosch Packaging has announced to settle a new production base in Chengdu, the new harbor of fast economic growth region in Western China.
Based in Waiblingen near Stuttgart, Germany, and employing 5,000 associates, the Bosch Packaging Technology division is one of the leading suppliers of process and packaging technology. At over 30 locations in more than 15 countries worldwide, a highly-qualified workforce develops and produces complete solutions for the pharmaceuticals, food, and confectionery industries. These solutions are complemented by a comprehensive after-sales service portfolio. A global service and sales network provides customers with local points of contact.
In China, the Bosch Group manufactures and markets automotive original equipment and aftermarket products, industrial drives and control technology, packaging technology, solar energy products, power tools, security and communication systems, thermotechnology, household appliances. Having established a regional presence in China since 1909, Bosch employs over 30,200 associates in 51 legal entities and facilities, with consolidated sales of 42.3 billion CNY in fiscal 2011.
The Bosch Group is a leading global supplier of technology and services, active in the fields of automotive technology, energy and building technology, industrial technology, and con-sumer goods. According to preliminary figures, more than 306,000 associates generated sales of 52.3 billion euros in 2012. The Bosch Group comprises Robert Bosch GmbH and its more than 350 subsidiaries and regional companies in some 60 countries. If its sales and service partners are included, then Bosch is represented in roughly 150 countries. This worldwide development, manufacturing, and sales network is the foundation for further growth. Bosch spent some 4.5 billion euros for research and development in 2012, and applied for over 4,700 patents worldwide. The Bosch Group's products and services are designed to fascinate, and to improve the quality of life by providing solutions which are both innovative and beneficial. In this way, the company offers technology worldwide that is "Invented for life."