A long-standing automation partnership between a Swiss machine builder and one of the world’s leading manufacturers of industrial robots is aiming to help transform the pharmaceutical supply chain in Europe with the launch of what is believed to be the ‘smallest’ automated palletising cell for vials and pre-filled syringes.

Swiss-based Robotronic has partnered with Mitsubishi Electric’s Factory Automation EMEA division for more than two decades. Now, the two organisations are collaborating together on a new low-footprint cell to help the pharmaceutical industry overcome record-high shortages across Europe in recent years for medicines ranging from children’s cough syrups through to antibiotics and even cancer treatments.

The growing demand, which has impacted patient treatment and quality of life, has led the European Medicines Agency to increasingly focus on one of the main causes of shortages – manufacturing and quality issues – with the aim of ultimately strengthening the fragile pharmaceutical supply chain.

Mike Weber, founder of Robotronic, says faster production is required to shorten lead times and cope with the ever-increasing demand. “We are a Swiss company concentrating on machine building with robotic applications for the pharmaceutical industry, including everything from de-nesting and re-nesting, through to de-traying, re-traying, and palletising. We have specific expertise in vial and pre-filled syringe handling, offering solutions that deliver maximum efficiency with a small footprint, and enabling pharmaceutical manufacturers to rise to the challenges in their supply chain.”

One of the key challenges for Robotronics is compliance. “Pharmaceutical consistency is about more than quality,” says Mike. “It is also about regulatory compliance and safety.

“To get the required productivity, we need two robots working very closely together at high-speed, but we also need the assurance that the delicate products being handled will not be damaged in the process.”

The Robotronic choice is Mitsubishi Electric, specifically the FR series, a highly flexible robot with compact arm sizes that is equipped with SoftTouch technology.

The result is a small footprint automation solution with increased productivity for handling pallets as small as 120cm x 80cm. Most importantly, the FR series has built-in compliance control that offers soft touch capability that delivers zero product damage with no glass-to-glass contact, no broken glass and is easy-to-clean.

“The challenge was to have two robots operating side by side in a confined environment without compromising speed or precision,” says Mike. “With Mitsubishi Electric’s help, we have two robots driving at full speed within millimetres of each other with no possibility of collision. This enables our cells to process up to 600 products a minute, without really challenging the robots.”

He concludes: “The relationship between Robotronic and Mitsubishi Electric is a true technological partnership – a combination of deep pharmaceutical process expertise allied to best-in-class robotic technology. Together, we believe we can develop machines that can shorten lead times and create a more robust pharmaceutical supply chain.”

Stefan Knauf, Division Manager at Mitsubishi Electric Factory Automation – German Branch, adds: “The biggest challenge was enabling Robotronic to safely and continuously operate two robots side-by-side in a confined environment, without compromising speed or precision. Our FR series robots with additional servo axis perfectly matched their requirements to deliver high throughput from a small footprint.

“The unique, built-in compliance control also allows the robots to gently handle glass vials without the risk of damage. Ultimately, in pharmaceutical production, consistency isn’t just about quality, it is about regulatory compliance and safety. Our relationship with Robotronic is a true technological partnership. Mike and his team bring deep pharmaceutical process expertise and we bring robotics innovation.”

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First introduced by the European Union (EU) on 10 December 2024, the CRA aims to safeguard consumers and businesses across Europe when purchasing software or hardware products with a digital component. Applying to all products connected directly or indirectly to another device or network, it establishes mandatory cybersecurity requirements that manufacturers and retailers must incorporate into the planning, design, development and maintenance of their products to continue selling them across the EU.

With fewer than 18 months to go before 11 December 2027 – when the main obligations of the Act are due to apply from – David Bean, Business Development Group Manager at Mitsubishi Electric – Factory Automation Systems UK, has warned that those who fail to comply with the legislation from this date will no longer be able to sell affected products to EU markets without a compliant CE mark.

“The introduction of the CRA is, of course, a positive development for end-users, who will benefit from improved security measures to defend against cyberattacks,” David explains. “However, for many machine builders, it could mean a fundamental shift in their system design, with the cybersecurity requirements that they must meet to sell into the EU set to become far more stringent as a result.

“To ensure compliance, machine builders must make sure that the equipment they manufacture is secure by design, rather than treating cybersecurity as a mere add on. This would involve considering the potential threats to a machine, incorporating appropriate security features to minimise the attack vector and providing transparency around the implementation of these features. Finally, OEMs must ensure any products with a digital element that are part of their machine build have a certificated process for managing exposed vulnerabilities that may over time be exposed in them.”

Specifically, manufacturers must ensure that products are designed, developed and produced in line with the essential cybersecurity requirements set out in Annex I of the regulation, and also carry out a cybersecurity risk assessment to identify relevant risks, determining the actions necessary to negate them. Furthermore, machine builders will need to choose from several conformity assessment procedures to demonstrate their compliance with the requirements.

Whilst machines as a whole fall under the CRA, so too do any components used within, which are classed by the CRA as products with a digital element (PDEs), such as PLCs, HMIs and drives. These components are likely to be classed in either the ‘Important’ or ‘Critical’ sections of the regulation’s framework for categorising a product’s cybersecurity risk and potential impact. Those marked as ‘Critical’ are subject to the most rigorous compliance measures due to their critical functions and potential impact on the health, security or safety of users.

Machine builders must also ensure that the PDEs they use are compliant with the CRA, obtaining appropriate documentation from the PDE’s manufacturer.

“To prepare for full implementation of the CRA, machine builders should be working with their supply chain now to ensure that they are ahead of the curve and ready to sell their products into European markets in line with the new requirements,” David continues. “After all, 18 months isn’t a long time at all when it comes to machine design, which is precisely why it’s so important that machine builders start planning now.

“We at Mitsubishi Electric appreciate that navigating the various requirements set out by the CRA can seem complex and daunting to many machine builders. We also recognise how important it is to work with reputable and reliable suppliers who understand the regulation and have their products certified against it.

“We are proud to offer support and assistance to achieve compliance with the CRA, with features built into our processes, such as certified product vulnerability management to IEC 62443-4-1. As such, we are in strong position to help our machine builder community on their journey to compliance with the new legislation.”

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The UK-headquartered specialist technical distributor will now offer the full suite of Mitsubishi Electric automation products and services, specifically variable speed drives, motion control, PLCs, HMIs, robots and licensed training.

As part of the agreement, Kempston Controls will make an immediate investment in training, technical and service support, including a sizeable investment in stock at distribution facilities that service customers nationwide.

Kempston Controls aims to use the agreement as a springboard to target new sectors with automation solutions, particularly the process industries including key verticals such as pharmaceutical and food and beverage.

Damian Wynne, Managing Director at Kempston Controls, says the agreement completes Kempston Controls’s automation offering. “This is Kempston Controls’ biggest move in a decade and a very exciting new venture that opens up significant opportunities for both companies. This agreement fills a gap in our technical capability and enables us, with Mitsubishi Electric’s support, to provide full turnkey automation solutions to our customers.

“Our commitment to this agreement is clearly demonstrated by our sizeable investment in stock, training and support and we are confident that together we can provide outstanding technical solutions for our customers and grow our respective businesses.”

Kempston Controls employs 300 staff with operations in the UK, including distribution sites in Earls Barton in Northamptonshire and Huddersfield, along with manufacturing sites in Manchester and Holyhead. Overseas, the company has distribution centres and sales support in Ireland and UAE, along with a sales support in North America, India and Sri Lanka.

Mitsubishi Electric recently attended Kempston Controls’s two-day ‘Plugged-In’ event with excellent feedback from customers. “The reaction from our customer base was very positive,” says Damian. “Our customers can see that this agreement will enable us to provide an end-to-end automation solution from design and technical support through to aftersales service that is market leading in the UK.”

Mike Cairns, Divisional Director of Mitsubishi Electric’s Automation System Division in the UK, comments: “This agreement is about more than bringing another distributor onboard. Our strategy is to develop incremental business for both partners by increasing market reach and penetration.

“There are strong synergies between the two companies with Kempston Controls adding a further dimension to our channel strategy and will have a very strategic role in the development of Mitsubishi Electric’s portfolio of automation solutions in the UK market.

“Most importantly, our sales and technical teams will work closely together, with the Kempston Controls team focused on market serve and our own Mitsubishi Electric team focused on market creation – all for the benefit of the end-user.”

Hartmut Putz, President, Factory Automation EMEA, Mitsubishi Electric, says the agreement is part of a long-term strategy. “Mitsubishi Electric’s Automation Systems Division is on a journey to increase its market share in Europe. In the UK, we are transitioning from being a stable business to a growth business, moving away from being a product-focused company to a solutions provider, focused on select market segments. Kempston Controls has a very complementary approach with a multi-level service capability that mirrors our own approach to the market.”

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The comprehensive range of packaged life cycle management services includes 24/7 service contracts, robot maintenance contracts, system health checks, obsolescence reporting, legacy migration solutions, power quality and harmonic surveys, energy management surveys, consultancy services, spares inventory management services and people development training.

Selected services within the life cycle management portfolio support both Mitsubishi Electric automation equipment, as well as other mainstream automation vendors’ equipment.

Chris Evans, Strategic Development Manager at Mitsubishi Electric Automation Systems Division, said: “We’re excited to be introducing our enhanced lifecycle management solutions, helping production plants to address the critical maintenance challenges that they face.

“As a life cycle partner, we remain steadfastly committed to supporting customers throughout their entire production journey, providing maintenance services for generations of our automation equipment, as well as that of other mainstream automation vendors.

“If you would like to discover how we can help meet your critical maintenance challenges enhance production quality and sustainable plant performance, I would encourage you to get in touch.”

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These new robots enhance industrial automation through high-speed operation, easy installation, and exceptional efficiency. Compact and lightweight, they are ideal for manufacturers aiming to boost productivity while navigating space and weight constraints.

Engineered with versatility in mind, the MELFA RH-CRH series is a perfect fit for a wide range of applications, including assembly, coating, and precision conveyance. With maximum reach radii ranging from 600mm to 1000mm and payload capacities of up to 10kg and 20kg, respectively, the RH-10CRH and RH-20CRH offer performance and adaptability to meet various production needs.

The RH-10CRH is designed for transportation and assembly in the food and automotive industries, while the RH-20CRH specialises in handling and packaging heavy items. Their lightweight design and compact structure allow for seamless integration into even the most restricted workspaces, maximising operational flexibility.

The MELFA RH-CRH series robots are equipped with innovative battery-less motors, which removes the need for periodic battery replacements. This reduces maintenance downtime and costs and effectively eliminates the risk of losing the robot’s positional origin (home position) due to battery exhaustion. As a result, the robots deliver consistent reliability, even during long production schedules or after extended downtime periods.

These improvements to productivity are amplified by a simplified design that significantly reduces the number of components, resulting in up to 69% weight reduction compared to previous models. This lowers installation and facility costs while enhancing long-term operational reliability, continuous operation performance, and overall productivity. Furthermore, the integrated wiring and air piping within the robot arm reduce wiring complexity and simplify setup.

The MELFA RH-CRH series also offers advanced functionality, tracking operations, support for 3D and 2D vision sensors, and force sensing, ensuring precise performance for high-speed tasks. Compatibility with CC-Link IE Field Basic, a gigabit industrial Ethernet network, enables seamless integration into existing production networks and Mitsubishi Electric Factory Automation products, making it ideal for digital transformation in manufacturing. Its optional safety features ensure secure operation in collaborative environments.

“With the MELFA RH-CRH series, we’ve created a solution that delivers exceptional performance and addresses the practical challenges our customers face in modern manufacturing,” said Keisuke Matsumura, Development Section Team Leader. “These robots alone demonstrate our commitment to innovation by helping manufacturers enhance productivity and efficiency.

“Additionally, when combined with other Mitsubishi Electric’s software advances – such as MELSOFT VIXIO enabled AI visual inspection, the creation of digital twins using MELSOFT Gemini – the expansion of automation, additional cost savings and system benefits can be achieved.”

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The MELSEC iQ-R safety local IO modules offer significant advantages in industries where precision and safety are paramount. By eliminating the need for additional safety relays, the safety output module (RY48PT20S-TS) supports a maximum load of 2A per point, totalling 16A, ensuring cost savings and optimising cabinet space. This expansion of the safety lineup allows businesses to control machines and processes without compromising safety.

The compact design of the safety local IO modules allows for seamless integration next to your iQ-R safety modules. With 16 single input points on the RX40NC6S-TS and 8 single output points on the RY48PT20S-TS, these modules offer flexibility and high-speed safety digital IO, catering to the diverse needs of industries such as automotive, food and beverage, life sciences and machine builder. It’s crucial for keeping workers safe and ensuring the factory runs without accidents.

Direct connection to the MELSEC iQ-R bus ensures faster reaction times, enhancing operational efficiency compared to safety over ethernet solutions. This advancement not only boosts productivity but also underscores Mitsubishi Electric’s commitment to delivering innovative, reliable solutions for industrial automation.

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Founded in 2014, HAL Robotics’ recently launched ‘decode’ software was developed to give operators and those with expert process knowledge the ability to adapt robotic tasks without any programming.

Based on the HAL Robotics Framework, it gives systems integrators and robot users the means to set up complex robotic toolpaths, simulate and validate procedures, and automatically send programs to the robots for execution. As a result, ‘decode’ helps remove hard-to-automate, varied and laborious tasks that previously required constant human input.

HAL Robotics’ partnership with Mitsubishi Electric means the software can now be integrated across the company’s range of small-scale 6-axis MELFA industrial robots. This provides stakeholders from across industry the ability to automate non-uniform tasks without the extensive set-up and training investments normally associated with bespoke solutions.

Sebastian Andraos, CEO and Co-Founder of HAL Robotics comments: “Automation has traditionally been associated with repeatable applications. By contrast, many manufacturing tasks requiring intricate manipulation of parts and non-uniform results are often viewed as too complex to be carried out by industrial robots. Our ‘decode’ software aims to upend these assumptions.

“By giving operators the opportunity to rapidly influence and change processes to suit the nuances of individual applications, reliance on integrator input can be reduced. Our new partnership with Mitsubishi Electric will allow us to increase access to automation technologies and plug a skills gap often found on factory floors regardless of sector.”

Barry Weller, Product Manager for Mechatronics at Mitsubishi Electric Automation Systems UK, comments: “The importance of HAL Robotics’ ‘decode’ software cannot be underestimated. Allowing operators to more easily integrate their human experience and industry knowledge into key processes and non-uniform manufacturing will be key to improving end-user efficiency, especially given the skills shortage that continue to affect the manufacturing sector.

“We’re looking forward to the future with HAL Robotics and excited to see how its ‘decode’ software will be implemented across multiple sectors.”

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Delivering enhanced user-friendliness, and with operators that are new to robotics in mind, the update can help users greatly streamline the set-up of automated applications.

Both entry-level and experienced users can benefit from the new additions to RT Toolbox3 and iQ Works2. The latest update adds an intuitive graphical user interface that features ‘drag-and-drop’ building blocks to the programming environment. This enables the creation of flowchart diagrams to quickly set up and simulate robot workflows without requiring any specialist knowledge.

The pre-coded modules feature a configuration wizard that helps users to insert the parameters needed for the machine to move, pick, pause and repeat. As a result, it is possible to fully customise the robot actions and benefit from maximum flexibility, ultimately making it even easier to deploy industrial robots.

The tool mirrors the framework used to set up and run the MELFA Assista collaborative robot (cobot). Therefore, any operator that has experience with this system will be able to interact with industrial robots using a familiar environment whilst having the option to compare the visual flowcharts with the automatically generated scripts. This will support users in advancing their programming skills and offers a unique educational platform to interact with the two programming forms. Developing a company’s future workforce has never been easier.

Barry Weller, robotics product manager at Mitsubishi Electric, comments: “Industrial robots are generally misperceived as time, resource and cost intensive as well as too complex to be used for entry-level applications. The latest additions to our software platforms expand the tools available to show this is not the case. Mainly aimed at first-time users, our graphical programming interface makes it extremely easy to configure and install any type of industrial robot, so virtually anyone can do it.

“More experienced engineers can also benefit from this update, as it can help simplify and reduce their programming time. This is why we have made the new functions available to all customers – new or existing. Robots are one of the foundations for the factories of the future and we want to maximise accessibility to help companies improve and futureproof their operations.”

The update is automatically included in recently purchased robot packages.

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Automated R&D and testing laboratories where cobots work alongside operators are no longer a vision of the future, but rather a reality of the present. Whether they are used to support development activities aimed at discovering new medicaments, collaborative solutions are already changing the way we operate and, ultimately, pharmaceutical manufacturing as we know it. Easy to program and install, they are also ideal for entry-level automation applications.

Collaborative and industrial robots are increasingly used in a wide range of industrial activities. In the last decade, the global sales volume of industrial robots tripled, with up to 422,000 units shipped worldwide every year. Cobots represent nearly 5% of this total and this is continuing to increase annually.

The high adoption rate for robotic solutions is primarily driven by the vast benefits they can deliver. Robots improve productivity and throughput while delivering high accuracy and reproducibility, leading to consistent production quality.

Collaborative robot solutions are particularly attractive in the pharmaceutical sector. In effect, manufacturing companies in this sector accounted for 66.9% of the entire pharmaceutical robot market in 2020 and it is anticipated to be the fastest growing in the period from 2021 to 2028. While traditional industrial robots held 64.1% of the market share in 2020, many pharmaceutical companies have been replacing them with cobots to increase flexibility and efficiency.

In addition, they typically require smaller initial investments, particularly if used in R&D or testing laboratories, where process revalidation is not required. They are also easier to integrate into existing facilities, as no physical barriers are required to ensure a safe working environment. One of the biggest advantages, however, is how intuitive and easy they are to use and interact with.

Making programming instinctive

Cobots utilise visual programming languages and graphical user interfaces that let users sequence the process and manipulate key functions without any coding. This significantly reduces programming complexity. For example, Mitsubishi Electric’s MELFA Assista cobot is coupled with an intuitive, touch-enabled engineering software, called RT VisualBox. This software supports the creation of operating sequences by linking block diagrams in a chain of events.

External devices, such as vision systems, can be connected to the cobot by using a software wizard within RT VisualBox that guides them through each step of the setup process. It is also possible to automatically perform key functions, such as the calibration of a coordinate system using Artificial Intelligence (AI).

To make things even easier, the MELFA Assista offers an additional hand-guided teaching function. With it, the cobot can be manually guided into a position, which is then added to the work sequence by pressing a button on the robotic arm.

These functionalities help operators create even highly sophisticated applications without any prior programming knowledge. Installation and setup can be streamlined and businesses can start using them almost instantly to improve medicament development and quality control activities. These elements are also extremely beneficial to companies at the beginning of their digital transformation journey and help users grow their confidence and skills in factory automation. There is no need for operators to have a high level of expertise in robotics or programming.

This also helps companies to develop their own in-house expertise and evolve over time, which can then support the use of more complex solutions, such as conventional industrial robots. Ultimately, businesses can increase their automation literacy and create highly effective setups that meet their specific needs and requirements. The implementation of robots in laboratories, for example, can then support their use in production lines, offering a quick return on investment (ROI) and making revalidation a successful investment.

Futureproofing education

Finally, the ease of use of a cobot such as the MELFA Assista can be key in meeting current and future workforce training requirements. Being able to work with robots, and all other automation components that make up smart factories, will be essential for the plant engineers of tomorrow. This means being able to set up these machines, interact and inspect them, as well as conduct maintenance activities.

Improving skill provision systems and upgrading education policies to advance technology skills is therefore becoming increasingly important. Collaborative robots can further support workforce development, as they remove entry barriers and contribute to increased ‘robot literacy’. By implementing cobots, forward-thinking businesses can benefit from automated processes and also assist their staff in developing key skills, adding value to their operations in the long run.

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Smart pharmaceutical manufacturing can do more than drive up productivity. It can transform the lives of patients by providing access to high-quality medicines while also improving the sustainability of operations and contributing to net zero policies. As a result, pharmaceutical companies can help to protect both people and the environment.

The future of pharmaceutical manufacturing, also known as Pharma 4.0, is based on data-driven technologies. These can generate in-depth knowledge on processes and activities, share this information with key equipment and automatically act upon this intelligence in real-time to optimise entire production lines.

This digital transformation of pharmaceutical operations can make businesses more lean and agile, delivering key opportunities in a number of areas beyond the shopfloor. In particular, smart manufacturing can help companies improve their environmental footprint.

The pharmaceutical industry is considered a major emitter, producing 55% more greenhouse gases than the automotive sector. As a result, businesses in this market will need to invest in key actions to help facilitate their journey to net zero. Digital transformation technologies offer a unique opportunity to support net zero policies with quick ROIs. In addition to forming a gateway to green manufacturing, they can also enhance the competitiveness of pharmaceutical manufacturers in a demanding marketplace, making digitalisation a particularly appealing strategy.

Pharma 4.0 is green

Well-designed automation solutions can optimise resource utilisation, reducing both waste and rework. Mitsubishi Electric’s specialist teams have supported a multitude of projects in the pharmaceutical and life sciences sectors, delivering improvements using customised automated systems. For example, smart process control solutions and robotics can improve yield and process performance whilst reducing energy consumption and thus improve manufacturing sustainability metrics.

These technologies can also reduce emissions, production time and costs, which in turn benefits both businesses and patients. In effect, it is estimated that Pharma 4.0 will save 30 minutes per year for each clinical trial patient and cost savings for customers of £1 billion are expected.

As the manufacture of increasingly advanced treatments and medical equipment becomes more expensive and resource intensive, the utilisation of automation offers pharmaceutical companies an opportunity to thrive. By leveraging state-of-the-art components, such as Mitsubishi Electric’s range of robots, controllers, drives, HMIs and MaisartTM based AI technologies, businesses can meet ambitious environmental goals while creating highly responsive production facilities.

To learn more about how industrial automation can help pharmaceutical manufacturers improve their environmental footprint and operations, click here to download Mitsubishi Electric’s white paper ‘Advancing pharmaceutical manufacturing now – Key automation technologies, applications and real-world benefits’.

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